Engine Controls - Tests W/codes - 2.5L VIN [N]: Diagnosis Dodge Avenger I

SYSTEM DIAGNOSTICS

Note. Self-diagnostic tests are written specifically for Chrysler's Diagnostic Readout Box (DRB). If using a generic scan tool, ensure it is OBD-II certified. A generic scan tool may not be capable of performing all necessary test functions. Malfunction Indicator Light (MIL), also known as CHECK ENGINE light can be used, but has limited diagnostic capability.

DIAGNOSTIC PROCEDURE

If no faults were found while performing appropriate BASIC DIAGNOSTIC PROCEDURES, proceed with self-diagnostics. Always perform a visual inspection before attempting to diagnose engine control system problems. See VISUAL INSPECTION under SELF-DIAGNOSTIC SYSTEM. Retrieve DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES under SELF-DIAGNOSTIC SYSTEM.

VISUAL INSPECTION

Most driveability problems in the engine control system result from faulty wiring, poor electrical connections, improper wire routing, or leaking air and vacuum hose connections. Inspect all engine control system components, hoses, connectors and wiring for damage before proceeding with system testing.

RETRIEVING DIAGNOSTIC TROUBLE CODES

Note. When using Chrysler's Diagnostic Readout Box (DRB-III) scan tool, the scan tool will be to identify or display all DTCs for system diagnosis. When using generic scan tool, it will be necessary to use Malfunction Indicator Light (MIL) on instrument panel and generic scan tool to retrieve Diagnostic Trouble Codes (DTCs). Not all DTCs can be retrieved using generic scan tool and MIL. When using MIL to retrieve DTCs, some DTCs have more than one meaning. The MIL is unable to distinguish between different failures for a specified component. For example, there are 4 different possible failures for the downstream oxygen sensor system, but the MIL can only identify a downstream oxygen sensor failure by flashing a DTC 21, but the scan tool will be able to distinguish between the different failures.

Note. When using generic scan tool, scan tool is not able to identify all possible DTCs. As an example, generic scan tool may not be able to identify or display a DTC for a malfunctioning A/C clutch relay circuit or A/C pressure sensor, but these DTCs will be displayed by the MIL.

CLEARING DIAGNOSTIC TROUBLE CODES

Turn ignition off. Turn ignition on and follow scan tool screen prompts to erase Diagnostic Trouble Codes (DTCs).

INACTIVE TROUBLE CODE CONDITION

This procedure applies if you have been sent here from diagnostic tests and have just attempted to simulate the condition that initially set the Diagnostic Trouble Code (DTC). The following additional checks may assist in identifying a possible intermittent problem

1. Visually inspect related wiring harness connectors for broken, bent, pushed out or corroded terminals.
2. Visually inspect related wiring harnesses for chafed, pierced or partially broken wires.
3. Check all pertinent Technical Service Bulletins (TSBs).

SELF-DIAGNOSTIC TESTS

Note. Both Malfunction Indicator Light (MIL) and a scan tool must be used to effectively diagnose this system. Before diagnosing an engine performance problem, see SELF-DIAGNOSTICS under INTRODUCTION to understand diagnostic system functions and abilities.

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION. In the following self-diagnostic tests, illustrations are courtesy of Chrysler Corp.

CHECKING SYSTEM FOR DIAGNOSTIC TROUBLE CODES

Note. Ensure battery is fully charged before proceeding with test.

1. Attempt to start engine. Crank engine for up to 10 seconds (if necessary). Diagnostic Trouble Codes (DTCs) may be retrieved using scan tool or Malfunction Indicator Light (MIL) on instrument panel.
2. If using MIL on instrument panel to check for DTCs, see RETRIEVING DIAGNOSTIC TROUBLE CODES proper procedure. Read DTC code flashed by the MIL.
3. If using scan tool to check for DTCs, connect scan tool to Data Link Connector (DLC). For Data Link Connector (DLC) location see scheme 1 Using scan tool manufacturer's instructions, read DTC message and code.
4. If scan tool displays NO RESPONSE, go to TEST NS-6A. If scan tool will not power up, check for loose cable connections or bad cable. If cable connections and cable are okay, check voltage at cavity No. 16 on 16-pin DLC. Voltage should be at least 11 volts. If voltage is not as specified, check wiring circuit and necessary fuses. See appropriate wiring diagram in «WIRING DIAGRAMS - 2.5L»(ref-24823) article in ENGINE PERFORMANCE.
5. If scan tool displays an error message, (i.e.; USER-REQUESTED COLD BOOT or USER-REQUESTED WARM BOOT), follow scan tool manufacturer's instructions. If scan tool displays a BUS failure (i.e. SHORT TO BATTERY), this indicates either a scan tool failure or BUS failure. To diagnose and correct BUS failures, see VEHICLE COMMUNICATIONS article in ACCESSORIES & EQUIPMENT section.
6. If DTCs are displayed, see DTC MESSAGES & CODES table and perform appropriate test(s). If no DTCs are displayed, refer to one of the following: For Driveability problems, perform TEST NTC-1A. For No-Start problems, perform TEST NS-SEL. For Speed (Cruise) Control problems, perform TEST SC-1A. See appropriate CRUISE CONTROL SYSTEMS article in ACCESSORIES & EQUIPMENT. For Charging system problems, perform TEST CH-1A. See GENERATORS & REGULATORS article in STARTING & CHARGING SYSTEMS.

Note. Some Diagnostic Trouble Codes (DTCs) have more than one meaning. Malfunction Indicator Light (MIL) is unable to distinguish between different failures. As an example, there are several different failures possible for the oxygen sensor (O2S) system, MIL can only identify an O2S failure by flashing a DTC 21. MIL is capable of displaying all possible system failures.

Note. A scan tool may not be able to identify all possible Diagnostic Trouble Codes (DTCs). As an example, a scan tool may not be able to identify or display a DTC for a malfunctioning A/C clutch relay circuit. There are several DTCs which a scan tool cannot identify. The Malfunction Indicator Light (MIL) must be used to identify these malfunctions.

DTC MESSAGES & CODES

TEST TC-1A - NO CAM SIGNAL AT PCM

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, erase DTCs. Attempt to start engine. If engine will not start, crank engine for at least 15 seconds. Using scan tool, read DTCs. If NO CAM SIGNAL AT PCM returned, go to next step. If NO CAM SIGNAL AT PCM did not return, got to TEST TC-1C.
2. Turn ignition off. On 2.5L, go to next step. Disconnect Camshaft Position (CMP) sensor connector.
3. Disconnect distributor connector. Camshaft Position (CMP) sensor is located inside distributor. Go to next step.
4. Inspect connector for damaged or pushed out terminals. Repair as necessary. Perform TEST VER-2A. If connector is okay, go to next step.
5. Using an ohmmeter, check resistance between CMP sensor connector (harness side) ground circuit and ground. See CMP SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open ground circuit to harness splice. Perform TEST VER-2A.
6. Turn ignition on. Using a voltmeter, check voltage on CMP sensor connector (harness side) 8-volt supply circuit. See CMP SENSOR CONNECTOR WIRE IDENTIFICATION table. CMP SENSOR CONNECTOR WIRE IDENTIFICATION Application Wire Color CMP 8-Volt Supply Circuit (1) Yellow CMP Signal Circuit (1) Brown CMP Ground Circuit (1) (2) Black/Dark Green (1) Camshaft position sensor wire is located at distributor connector. (2) Ensure sensor ground is tested, not distributor ground.
7. If voltage is more than 7 volts, go to next step. If voltage is 7 volts or less, repair 8-volt supply circuit. Perform TEST VER-2A.
8. Turn ignition off. Connect a jumper wire to CMP sensor signal circuit. See CMP SENSOR CONNECTOR WIRE IDENTIFICATION table. Turn ignition on. Using scan tool, note CMP sensor signal state. While observing scan tool display, tap other end of jumper wire to CMP sensor ground circuit. See CMP SENSOR CONNECTOR WIRE IDENTIFICATION table.
9. If CMP state changes, go to TEST TC-1B. If CMP state does not change, turn ignition off. Disconnect PCM connectors. Using an ohmmeter, check resistance of CMP sensor signal circuit between CMP sensor connector (harness side) and PCM connector terminal No. 43 (sensor ground). See CMP SENSOR CONNECTOR WIRE IDENTIFICATION table and POWERTRAIN CONTROL MODULE WIRE IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open CMP sensor signal circuit. Perform TEST VER-2A. POWERTRAIN CONTROL MODULE WIRE IDENTIFICATION Application Wire Color PCM Terminal No. 43 (Sensor Ground Circuit) Black/Dark Green
10. Using an ohmmeter, check resistance between CMP sensor connector (harness side) signal circuit and sensor ground circuit. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair signal circuit for shorting to sensor ground circuit. Perform TEST VER-2A.
11. Using an ohmmeter, check resistance between CMP sensor connector (harness side) signal circuit and 8-volt supply circuit. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A. If resistance is less than 5 ohms, repair signal circuit for shorting to 8-volt supply circuit. Perform TEST VER-2A.

TEST TC-1B: NO CAM SIGNAL AT PCM

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS article.

1. Turn ignition off. If vehicle is equipped with a 2.5L engine, go to next step. If vehicle is equipped with a 2.0L or 2.4L engine, go to step 3 .
2. Remove distributor cap and rotor. Inspect pulse ring for damage or misalignment. If pulse ring is okay, replace CMP position sensor. Perform TEST VER-2A. If pulse ring is not okay, repair or replace distributor pulse ring as necessary. Perform TEST VER-2A.
3. Remove CMP sensor from engine. Inspect CMP sensor target magnet for damage or misalignment. If target magnet is okay, replace CMP sensor. Perform TEST VER-2A. If target magnet is not okay, repair or replace target magnet as necessary. Perform TEST VER-2A.

TEST TC-1C: NO CAM SIGNAL AT PCM

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS article.

1. Attempt to start engine. If engine will not start, go to TEST NS-SEL. If engine starts, condition to set trouble code is not present at this time. NO CAM SIGNAL AT PCM DTC sets if signals are not received from CMP sensor when signals are present from Crankshaft Position (CKP) sensor. On 2.0L and 2.4L engines, go to next step. On 2.5L engine, go to step 3 .
2. On 2.0L and 2.4L engines, possible causes are: open or shorted 8-volt supply circuit, open sensor ground, open or shorted signal circuit, excessive clearance between sensor and target magnet, damaged target magnet, failed CMP sensor, failed PCM or broken timing belt. Go to step 4 .
3. On 2.5L engine, possible causes are: open 8-volt supply circuit, open sensor ground, open or shorted signal circuit, excessive clearance between sensor and sprocket, damaged sprocket, failed CMP sensor or failed PCM. Go to next step.
4. Repair any problems as necessary. Perform TEST VER-2A. If no problems were found, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.

TEST TC-5A - CHARGING SYSTEM VOLTAGE TOO LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Battery must be fully charged. Generator belt tension and condition must be okay. Using scan tool, read target charging voltage. If voltage is more than 15.1 volts, go to next step. If voltage is 15.1 volts or less, go to step 3).
2. Using scan tool temperature probe, read battery temperature sensor temperature. Using scan tool, measure ambient air temperature near PCM. If scan tool display is within 10 degrees of actual underhood temperature, go to next step. If scan tool display is not within 10 degrees of actual underhood temperature, replace Powertrain Control Module (PCM). Perform TEST VER-3A. NOTE: Before starting engine, ensure all test equipment wires are clear of moving engine parts.
3. Connect an external voltmeter between generator B+ terminal and battery positive terminal. Start engine. If voltage is .4 volt or less, go to next step. If voltage is more than .4 volt, repair B+ circuit for high resistance between generator and battery. Perform TEST VER-3A.
4. Turn ignition off. Connect an external voltmeter between generator case and battery negative terminal. Start engine. If voltage is .1 volt or less, go to next step. If voltage is more than .1 volt, repair generator ground for high resistance between generator case and battery negative terminal. Perform TEST VER-3A.
5. Manually set engine speed to 1600 RPM. Using scan tool, read and compare target voltage and charging voltage. If difference between target voltage and charging voltage is one volt or less, go to next step. If difference between target voltage and charging voltage is more than one volt, go to TEST TC-5B.
6. Return engine to idle speed. Turn engine off. For further testing, see appropriate GENERATORS & REGULATORS article in STARTING & CHARGING SYSTEMS.

TEST TC-5B - CHARGING SYSTEM VOLTAGE TOO LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect generator field connector and PCM connectors. Using an ohmmeter, check resistance of ASD relay output circuit between generator field connector and PCM connector. See ASD RELAY OUTPUT CIRCUIT IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open ASD relay output circuit. Perform TEST VER-3A. ASD RELAY OUTPUT CIRCUIT IDENTIFICATION Application Wire Color Generator Field Driver Connector Red PCM Connector Terminal No. 6 Black/Red
2. Using an ohmmeter, check resistance of generator field driver circuit between generator field connector and PCM connector. See GENERATOR FIELD DRIVER CIRCUIT IDENTIFICATION table. If resistance is less than 5 ohms, repair or replace generator. If resistance is 5 ohms or more, repair open generator field driver. Perform TEST VER-3A.

GENERATOR FIELD DRIVER CIRCUIT IDENTIFICATION

TEST TC-6A - CHARGING SYSTEM VOLTAGE TOO HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Battery must be fully charged. Generator belt tension and condition must be okay. Using scan tool, actuate generator field driver. Using a voltmeter, backprobe generator field connector, checking voltage on Dark Green wire. If voltage shifts low to high go to TEST TC-6B. If voltage does not shift low to high, go to next step.
2. Using scan tool, stop generator field actuation. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Disconnect generator field connector from back of generator. Using an ohmmeter, check resistance of PCM connector terminal No. 4 Dark Green wire. If resistance is less than 5 ohms, repair short to ground on generator field driver circuit. Perform TEST VER-3A. If resistance is 5 ohms or more, go to next step.
3. Using an ohmmeter, check resistance between either generator field terminal (on back of generator) and ground. If resistance is less than 5 ohms, repair or replace shorted generator. Perform TEST VER-3A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-3A.

TEST TC-6B - CHARGING SYSTEM VOLTAGE TOO HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, stop generator field driver actuation. Using scan tool, read target charging voltage. If target charging voltage is more than 13 volts, go to step 3). If target charging voltage is 13 volts or less, go to next step.
2. Using scan tool temperature probe, read battery temperature sensor temperature. Using scan tool, measure ambient air temperature near PCM. If scan tool display is within 10 degrees of actual underhood temperature, go to next step. If scan tool display is not within 10 degrees of actual underhood temperature, replace Powertrain Control Module (PCM). Perform TEST VER-3A.
3. Start engine. Manually set engine speed to 1600 RPM. Using scan tool, read and compare voltage and target charging voltage. Observe voltage for up to 5 minutes (if necessary) for a one volt difference between voltage and target charging voltage. If difference between voltage and target charging voltage is one volt or less, go to next step. If difference between voltage and target charging voltage is more than one volt, replace Powertrain Control Module (PCM). Perform TEST VER-3A.
4. Return engine to idle speed. Turn engine off. For further testing, see appropriate GENERATORS & REGULATORS article in STARTING & CHARGING SYSTEMS.

TEST TC-10A - AUTO SHUTDOWN RELAY CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Scheme 91

Scheme 92

1. Using scan tool, actuate Auto Shutdown (ASD) relay. Listen for clicking sound at ASD relay. ASD relay is located in left rear corner of engine compartment. If ASD relay is clicking, go to next step. If ASD relay is not clicking, go to step 5).
2. Condition to set trouble code is not present at this time. AUTO SHUTDOWN RELAY CONTROL CIRCUIT DTC sets if an open or shorted condition is detected in ASD relay control circuit. Possible causes are: ASD relay coil open or shorted, fused battery positive circuit open, ASD relay control circuit open or shorted, inoperative driver in Powertrain Control Module (PCM), PCM failure or poor connections. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. Start engine. Wiggle wiring harness from ASD relay to PCM. If engine misfired or stalled, repair wiring harness as necessary. Perform TEST VER-2A. If engine did not misfire or stall, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. Disconnect ASD relay. Using a voltmeter, check voltage on ASD relay connector fused B+ circuit. (Scheme 91) When checking fused B+ circuit, ensure circuit is tested at both terminals (one at a time) of ASD relay connector. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused B+ circuit. See ASD RELAY CONNECTOR WIRE IDENTIFICATION table. Perform TEST VER-2A. (Scheme 91): Identifying ASD Relay Connector Terminals & Location (Scheme 92): Testing Relay
6. Using an ohmmeter, check resistance between ASD relay terminals. (Scheme 92) If resistance is less than 100 ohms, go to next step. If resistance is 100 ohms or more, replace ASD relay. Perform TEST VER-2A.
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of ASD relay control circuit at ASD relay connector. See ASD RELAY CONNECTOR WIRE IDENTIFICATION table and Figs. (Scheme 91) for wire identification. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in ASD relay control circuit. Perform TEST VER-2A.
8. Using an ohmmeter, measure resistance of ASD relay control circuit between ASD relay connector and PCM connector. See ASD RELAY CONNECTOR WIRE IDENTIFICATION table, PCM CONNECTOR WIRE IDENTIFICATION table, and see scheme 2 - see scheme 37 for wire identification. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open ASD relay control circuit. Perform TEST VER-2A.

TEST TC-11A - GENERATOR FIELD NOT SWITCHING PROPERLY

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, erase trouble codes. Using scan tool, actuate generator field driver circuit. Using a voltmeter, backprobe generator field connector ASD relay output circuit. Generator field connector is located on back of generator. See GENERATOR FIELD CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-3A. GENERATOR FIELD CONNECTOR WIRE IDENTIFICATION Application Wire Color ASD Relay Output Circuit Red Generator Field Driver Circuit Dark Blue
2. Using a voltmeter, backprobe generator field connector generator field driver circuit. See GENERATOR FIELD CONNECTOR WIRE IDENTIFICATION table. If voltage shifts from low to high, go to next step. If voltage does not shift from low to high, go to step 5).
3. Condition to set trouble code is not present at this time. GENERATOR FIELD NOT SWITCHING PROPERLY DTC sets when Powertrain Control Module (PCM) tries to regulate generator field with no result during monitoring. Possible causes are: field driver circuit open or shorted, generator internal open or short or PCM failure. Go to next step.
4. Wiggle wiring harness from generator to PCM. Using scan tool, read DTCs with actuator test still running. If generator field driver circuit failure returned, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-3A. If generator field driver circuit failure did not appear, no problem is found at this time. Test is complete. Perform TEST VER-3A.
5. Using scan tool, stop generator field driver activation. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Disconnect generator field connector from back of generator. Using an ohmmeter, check resistance of generator field driver circuit between generator field driver connector and PCM connector No. 4. See GENERATOR FIELD CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, repair open generator field driver circuit. Perform TEST VER-3A. If resistance is less than 5 ohms, go to next step.
6. Using an ohmmeter, check resistance between generator field terminals on generator. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair generator as necessary. Perform TEST VER-3A.
7. Using an ohmmeter, check resistance of generator field connector generator field driver circuit. See GENERATOR FIELD CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, repair short to ground on generator field driver circuit. Perform TEST VER-3A. If resistance is 5 ohms or more, replace Powertrain Control Module (PCM). Perform TEST VER-3A.

TEST TC-14A - RAD FAN CONTROL RELAY CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, actuate radiator fan relay. If both radiator fan motors are cycling on and off, go to next step. If both radiator fan motors are not cycling on and off, go to step 4).
2. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
3. With actuator test still running, wiggle wiring harness between radiator fan relay and PCM. Radiator fan relay is located in Power Distribution Center (PDC). If wiggling caused an interruption in radiator fan motor cycling, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If wiggling did not cause an interruption in radiator fan motor cycling, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
4. While still actuating radiator fan relay, using a voltmeter, backprobe radiator fan relay connector output circuit (Dark Green wire). If voltage is not cycling 0-B+ volts, go to next step. If voltage is cycling 0-B+ volts, repair or replace radiator fans or wiring between radiator fan relay and fan motors. Perform TEST VER-2A.
5. Disconnect radiator fan relay connector. Low speed fan relay is located in Power Distribution Center (PDC). Using a voltmeter, check voltage of radiator fan relay connector fused B+ circuit (Gray wire). If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Gray wire. Perform TEST VER-2A.
6. Turn ignition off. Using an ohmmeter, check resistance of radiator fan relay connector ground circuit (Black wire). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black wire. Perform TEST VER-2A.
7. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of PCM connector terminal No. 18 (Light Green wire). If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in Light Green wire. Perform TEST VER-2A.
8. Using an ohmmeter, measure resistance of radiator fan relay control circuit (Light Green wire) between radiator fan relay connector and PCM connector terminal No. 18. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Light Green wire. Perform TEST VER-2A.
9. Reconnect radiator fan relay connector. Using a jumper wire, connect one end of jumper wire to PCM connector terminal No. 18 (Light Green wire). Turn ignition on. Momentarily connect other end of jumper wire to ground. Observe radiator fan motors. If radiator fan motors actuated, replace PCM. Perform TEST VER-2A. If radiator fan motors did not actuate, replace radiator fan motor relay. Perform TEST VER-2A.

TEST TC-15A - SPEED CONTROL POWER RELAY CIRCUIT & SPEED CONTROL SOLENOID CIRCUITS

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn Speed Control (SC) on. Using scan tool, actuate Speed Control (SC) vent solenoid. If SC servo clicks, go to next step. If SC servo does not click, go to step 8).
2. Wiggle wiring harness between SC servo, brake switch and Powertrain Control Module (PCM). If wiggling did not cause an interruption of SC servo actuation, go to next step. If wiggling caused an interruption of SC servo actuation, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-4A.
3. Using scan tool, actuate SC vacuum solenoid. If SC servo clicks, go to next step. If SC vacuum solenoid does not click, go to step 8).
4. Wiggle wiring harness between SC servo and brake switch to PCM while scan tool is still actuating SC vacuum solenoid. If wiggling did not cause an interruption of SC servo actuation, go to next step. If wiggling caused an interruption of SC servo actuation, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-4A.
5. Condition to set trouble code is not present at this time. If SPEED CONTROL SOLENOID CIRCUITS DTC is being diagnosed, go to next step. SPEED CONTROL POWER RELAY CIRCUIT DTC sets when speed control power supply circuit is either open or shorted to ground. Possible causes are: open or shorted power supply circuit or failed SC vent solenoid. Go to step 7).
6. SPEED CONTROL SOLENOID CIRCUITS DTC sets when PCM actuates vacuum and vent solenoids, but solenoids do not respond. Possible causes are: solenoid control circuit open or shorted, vacuum or vent solenoid shorted or open, open or shorted speed control power supply circuit or PCM failure. Go to next step.
7. Inspect all related wiring and connectors and repair as necessary. If related wiring and connectors were repaired, perform TEST VER-4A. If no problems were found with wiring and connectors, test is complete. Perform TEST VER-4A.
8. Perform TC-15C.

TEST TC-15C - SPEED CONTROL POWER RELAY CIRCUIT & SPEED CONTROL SOLENOID CIRCUITS

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Disconnect Speed Control (SC) servo 4-pin connector. Turn ignition on. Put speed control on/off switch in ON position. DO NOT depress brake pedal during testing. Using a voltmeter, check voltage on SC servo connector Dark Blue/White wire. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, see appropriate CRUISE CONTROL SYSTEMS article.
2. Using an ohmmeter, check resistance on SC servo connector Black wire. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Black wire. Perform TEST VER-4A.
3. Turn ignition off. Reconnect SC servo connector. Disconnect Powertrain Control Module (PCM) connectors. Turn ignition on. Using a voltmeter, check voltage on PCM connector terminal No. 78 (Light Green/White wire). Record voltage. Using a voltmeter, check voltage on PCM connector terminal No. 80 (Black/Yellow wire). If voltage on both circuits is more than 9 volts, replace PCM. Perform TEST VER-4A. If voltage on both circuits is 9 volts or less, go to next step.
4. Turn ignition off. Disconnect SC servo 4-pin connector. Using an ohmmeter, check resistance of SC servo connector Light Green/White wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in Light Green/White wire. Perform TEST VER-4A.
5. Using an ohmmeter, check resistance of SC servo connector Black/Yellow wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in Black/Yellow wire. Perform TEST VER-4A.
6. Using an ohmmeter, check resistance of SC vacuum solenoid control circuit Light Green/White wire between SC servo connector and Powertrain Control Module (PCM) connector terminal No. 78. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Light Green/White wire. Perform TEST VER-4A.
7. Using an ohmmeter, check resistance of SC vent solenoid control circuit Black/Yellow wire between SC servo connector and PCM connector terminal No. 80. If resistance is less than 5 ohms, replace SC control servo. Perform TEST VER-4A. If resistance is 5 ohms or more, repair open Black/Yellow wire. Perform TEST VER-4A.

TEST TC-16A - A/C CLUTCH RELAY CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Scheme 93

1. Using scan tool, actuate A/C clutch relay. A/C clutch relay is located in Power Distribution Center (PDC). If A/C clutch relay is clicking, go to next step. If A/C clutch relay is not clicking, go to step 5).
2. Condition to set trouble code is not present at this time. A/C CLUTCH RELAY CIRCUIT DTC sets if an open or short is detected in A/C clutch relay control circuit. Possible causes are: relay coil open or shorted, fused ignition switch output circuit open, compressor clutch relay control circuit open or shorted, or inoperative circuit driver in Powertrain Control Module (PCM). Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. With scan tool still actuating A/C clutch relay, wiggle wiring harness from A/C clutch relay to PCM. If wiggling interrupted A/C clutch relay actuation, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If wiggling did not interrupt A/C clutch relay actuation, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. Disconnect A/C clutch relay. Using a voltmeter, check voltage on A/C clutch relay connector fused ignition switch output circuit Dark Green wire. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused ignition switch output circuit. Perform TEST VER-2A.
6. Using an ohmmeter, check resistance across A/C clutch relay terminals. (Scheme 93) If resistance is less than 100 ohms, go to next step. If resistance is 100 ohms or more, replace A/C clutch relay. Perform TEST VER-2A. (Scheme 93): Identifying A/C Clutch Relay Terminals
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of A/C clutch relay connector A/C clutch control circuit Dark Green wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in A/C clutch relay control circuit. Perform TEST VER-2A.
8. Using an ohmmeter, check resistance of A/C clutch relay control circuit Dark Green wire between A/C clutch relay connector and PCM connector terminal No. 64. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open A/C clutch relay control circuit. Perform TEST VER-2A.

TEST TC-17A - EGR SOLENOID CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, erase DTCs. Using scan tool, actuate EGR solenoid. Using scan tool, read DTCs. If scan tool displays EGR SOLENOID CONTROL CIRCUIT, go to step 5). If scan tool does not display EGR SOLENOID CONTROL CIRCUIT, go to next step.
2. Condition to set trouble code is not present at this time. EGR SOLENOID CIRCUIT DTC sets if EGR solenoid control circuit is not in its proper state when requested to operate by Powertrain Control Module (PCM). Possible causes are: EGR solenoid control circuit open or shorted, fused ignition switch output circuit open, EGR solenoid coil open or shorted, or PCM failure. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. With scan tool still actuating EGR solenoid, wiggle wiring harness from EGR solenoid to PCM. If wiggling interrupted EGR solenoid actuation, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If wiggling did not interrupt EGR solenoid actuation, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. Turn ignition off. Disconnect EGR solenoid connector. Turn ignition on. Using a voltmeter, check voltage on EGR solenoid connector fused ignition switch output circuit Black/White wire. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused ignition switch output circuit. Perform TEST VER-2A.
6. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of EGR solenoid control circuit Red/Dark Blue wire between EGR solenoid connector and PCM connector terminal No. 40. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open EGR solenoid control circuit. Perform TEST VER-2A.
7. Using an ohmmeter, check resistance of EGR solenoid control circuit Red/Dark Blue wire at EGR solenoid connector. If resistance is less than 5 ohms, repair short to ground in EGR solenoid control circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, go to next step.
8. Reconnect EGR solenoid connector. Turn ignition on. Using a voltmeter, check voltage on PCM connector terminal No. 40 Red/Dark Blue wire. If voltage is more than 10 volts, replace PCM. Perform TEST VER-2A. If voltage is 10 volts or less, replace EGR solenoid. Perform TEST VER-2A.
9. Turn ignition off. Disconnect PCM connector. Using an ohmmeter, check resistance of Gray/Yellow wire between EGR solenoid connector and PCM connector terminal No. 40. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Gray/Yellow wire. Perform TEST VER-2A.
10. Using an ohmmeter, check resistance of Gray/Yellow wire between EGR solenoid connector and ground. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on Gray/Yellow wire. Perform TEST VER-2A.
11. Using an ohmmeter, check resistance of EGR solenoid. If resistance is 25-75 ohms, replace PCM. Perform TEST VER-2A. If resistance is not 25-75 ohms, replace EGR solenoid. Perform TEST VER-2A.

TEST TC-18A - EVAP PURGE SOLENOID CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, erase DTCs. Using scan tool, actuate EVAP purge solenoid. Using scan tool, read DTCs. If scan tool displays EVAP PURGE SOLENOID CONTROL CIRCUIT, go to step 5). If scan tool does not display EVAP PURGE SOLENOID CONTROL CIRCUIT, go to next step.
2. Condition to set trouble code is not present at this time. EVAP PURGE SOLENOID CIRCUIT DTC sets after arming conditions are satisfied: not powering down, not already in limp-in, and more than 72 microseconds have passed since last solenoid actuation. The Powertrain Control Module (PCM) will set DTC if actual state of solenoid does not match intended state. Possible causes are: open or shorted control circuit, open fused ignition switch output circuit, open or shorted EVAP purge solenoid control coil, defective PCM, defective connector terminals or wiring. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. With scan tool still actuating EVAP purge solenoid, wiggle wiring harness from EVAP purge solenoid to PCM. If wiggling interrupted EVAP purge solenoid actuation, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If wiggling did not interrupt EVAP purge solenoid actuation, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. Turn ignition off. Disconnect EVAP purge solenoid connector. Turn ignition on. Using a voltmeter, check voltage on EVAP purge solenoid connector fused ignition switch output circuit Black/White wire. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused ignition switch output circuit. Perform TEST VER-2A.
6. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of EVAP purge solenoid control circuit Light Green Black wire, between EVAP purge solenoid connector and PCM connector terminal No. 68. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open EVAP purge solenoid control circuit. Perform TEST VER-2A.
7. Using an ohmmeter, check resistance of EVAP purge solenoid control circuit Light Green Black wire at EVAP purge solenoid connector. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in EVAP purge solenoid control circuit. Perform TEST VER-2A.
8. Reconnect EVAP purge solenoid connector. Turn ignition on. Using a voltmeter, check voltage on PCM connector terminal No. 68 Light Green Black wire. If voltage is more than 10 volts, replace PCM. Perform TEST VER-2A. If voltage is 10 volts or less, replace EVAP purge solenoid. Perform TEST VER-2A.

TEST TC-19A - INJECTOR NO. 3 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. If vehicle has a 4-cylinder engine, perform TEST TC-19E. If vehicle has an a 6-cylinder engine, go to next step.
2. Turn ignition off. Disconnect injector harness 10-pin connector. Using an ohmmeter, check resistance on injector harness connector (PCM side) between Yellow/Dark Green wire and Black/Red wire. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, perform TEST TC-19B.
3. Remove ohmmeter lead from Black/Red wire to ground. Observe ohmmeter reading. If ohmmeter reading is 5 ohms or more, go to next step. If ohmmeter reading is less than 5 ohms, repair short to ground on injector No. 3 driver circuit Yellow/Dark Green wire. Perform TEST VER-2A.
4. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector connector (PCM side) ASD relay output circuit Black/Red wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open Black/Red wire. Perform TEST VER-2A.
5. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance on PCM connector terminal No. 7 (injector No. 3 driver circuit) Yellow/Dark Green wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 3 driver circuit. Perform TEST VER-2A.
6. Using an ohmmeter, check resistance of injector No. 3 driver circuit, Yellow/Dark Green wire between injector connector (PCM side) and PCM connector terminal No. 7. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector driver No. 3 circuit. Perform TEST VER-2A.

TEST TC-19B - INJECTOR NO. 3 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 3 connector. Using an ohmmeter, check resistance of injector No. 3 ASD relay output circuit Black/Red wire between injector No. 3 connector and injector 10-pin connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open injector No. 3 ASD relay output circuit. Perform TEST VER-2A.
2. Using an ohmmeter, check resistance of injector No. 3 driver circuit Yellow/Dark Green wire between injector No. 3 connector and injector 10-pin connector. If resistance is less than 5 ohms, replace injector No. 3. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector No. 3 driver circuit. Perform TEST VER-2A.

TEST TC-19D - INJECTOR NO. 3 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 3 connector. Using an ohmmeter, check resistance of Dark Green/Orange wire between injector No. 3 connector and junction block No. 2 connector (injector side). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Dark Green/Orange wire. Perform TEST VER-2A.
2. Using an ohmmeter, check resistance of Yellow/White wire between injector No. 3 connector and junction block No. 1 connector (injector side). If resistance is less than 5 ohms, replace injector No. 3. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open Yellow/White wire. Perform TEST VER-2A.

TEST TC-19E - INJECTOR NO. 3 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect injector No. 3 connector. Using an ohmmeter, check resistance across injector No. 3 terminals. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, replace injector No. 3. Perform TEST VER-2A.
2. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector No. 3 connector ASD relay output circuit Black/Red wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open ASD relay output circuit. Perform TEST VER-2A.
3. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of PCM connector terminal No. 7 injector No. 3 driver circuit Yellow/Dark Green wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 3 driver circuit. Perform TEST VER-2A.
4. Using an ohmmeter, check resistance of injector No. 3 driver circuit Yellow/Dark Green wire between PCM connector terminal No. 7 and injector No. 3 connector. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector No. 3 driver circuit. Perform TEST VER-2A.

TEST TC-20A - INJECTOR NO. 2 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 2 connector. Using an ohmmeter, check resistance across injector No. 2 terminals. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, replace injector No. 2. Perform TEST VER-2A.
2. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector No. 2 connector ASD relay output circuit Black/Red wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open ASD relay output circuit. Perform TEST VER-2A.
3. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of PCM connector terminal No. 17 injector No. 2 driver circuit. See POWERTRAIN CONTROL MODULE WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 2 driver circuit. Perform TEST VER-2A.
4. Using an ohmmeter, check resistance of injector No. 2 driver circuit Yellow/Red wire. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more repair open injector No. 2 driver circuit. Perform TEST VER-2A.

POWERTRAIN CONTROL MODULE WIRE IDENTIFICATION

TEST TC-21A - INJECTOR CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Start engine. Allow engine to idle for at least 20 seconds. Using scan tool, read Diagnostic Trouble Codes (DTCs). If scan tool displays any INJECTOR CONTROL CIRCUIT codes with a run/start count of zero, go to step 5). If scan tool does not display any INJECTOR CONTROL CIRCUIT codes with a run/start count of zero, go to next step.
2. Condition to set trouble code is not present at this time. INJECTOR CONTROL CIRCUIT DTC sets if no inductive kick is sensed .18 milliseconds after injector turn off with no other injectors on. This DTC takes .64-10 seconds to set. Possible causes are: open or shorted injector driver circuit, open injector, open ASD supply voltage at injector or Powertrain Control Failure (PCM) failure. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. With engine idling, wiggle wiring harness from fuel injectors to PCM. If wiggling caused engine to misfire or stall, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If wiggling did not cause misfire or stall, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. See INJECTOR TROUBLE CODE table.

INJECTOR TROUBLE CODE

TEST TC-21B - INJECTOR NO. 1 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Perform TEST TC-21F. If vehicle has a 6-cylinder engine, go to next step.
2. Turn ignition off. Disconnect injector harness 10-pin connector. Using an ohmmeter, check resistance on injector harness connector (injector side) between Brown/White wire and Black/Red wire. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, perform TEST TC-21C.
3. Move ohmmeter lead from Black/Red wire to ground. Observe ohmmeter reading. If ohmmeter reading is 5 ohms or more, go to next step. If ohmmeter reading is less than 5 ohms, repair short to ground on injector No. 1 driver circuit Brown/White wire. Perform TEST VER-2A.
4. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector connector (PCM side) ASD relay output circuit Black/Red wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open Black/Red wire. Perform TEST VER-2A.
5. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance on PCM connector terminal No. 13 injector No. 1 driver circuit Light Green/Black wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 1 driver circuit. Perform TEST VER-2A.
6. Using an ohmmeter, check resistance of injector No. 1 driver circuit, Brown/White wire between injector connector (PCM side) and PCM connector terminal No. 13. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector driver No. 1 circuit. Perform TEST VER-2A.

TEST TC-21C - INJECTOR NO. 1 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 1 connector. Using an ohmmeter, check resistance of injector No. 1 ASD relay output circuit Black/Red wire between injector No. 1 connector and injector 10-pin connector . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open injector No. 1 ASD relay output circuit. Perform TEST VER-2A.
2. Using an ohmmeter, check resistance of injector No. 1 driver circuit Brown/White wire between injector No. 1 connector and injector 10-pin connector. If resistance is less than 5 ohms, replace injector No. 1. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector No. 1 driver circuit. Perform TEST VER-2A.

TEST TC-21E - INJECTOR NO. 1 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 1 connector. Using an ohmmeter, check resistance of Dark Green/Orange wire between injector No. 1 connector and junction block No. 2 connector (injector side). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Dark Green/Orange wire. Perform TEST VER-2A.
2. Using an ohmmeter, check resistance of White/Dark Blue wire between injector No. 1 connector and junction block No. 1 connector (injector side). If resistance is less than 5 ohms, replace injector No. 1. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open White/Dark Blue wire. Perform TEST VER-2A.

TEST TC-21F - INJECTOR NO. 1 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect injector No. 1 connector. Using an ohmmeter, check resistance across injector No. 1 terminals. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, replace injector No. 1. Perform TEST VER-2A.
2. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector No. 1 connector ASD relay output circuit Black/Red wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open ASD relay output circuit. Perform TEST VER-2A.
3. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of PCM connector terminal No. 13 injector No. 1 driver circuit Light Green/Black wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 1 driver circuit. Perform TEST VER-2A.
4. Using an ohmmeter, check resistance of injector No. 1 driver circuit Light Green/Black wire between PCM connector terminal No. 13 and injector No. 1 connector. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector No. 1 driver circuit. Perform TEST VER-2A.

TEST TC-25A - IDLE AIR CONTROL MOTOR CIRCUITS

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off for 10 seconds. Start engine. Allow engine to idle for 20 seconds. If engine will not idle, hold throttle open slightly to keep engine running. Using scan tool, actuate Idle Air Control (IAC) motor to 1400 RPM. If engine speed is 1300-1500 RPM, go to next step. If engine speed is not 1300-1500 RPM, go to step 7).
2. Using scan tool, actuate IAC motor to 900 RPM. If engine speed is 800-1000 RPM, go to next step. If engine speed is not 800-1000 RPM, go to step 7).
3. Condition to set trouble code is not present at this time. IDLE AIR CONTROL MOTOR CIRCUITS DTC sets if Powertrain Control Module (PCM) senses a short to ground or battery voltage on any 4 IAC driver circuits for 2.75 seconds while IAC motor is active. Possible causes are: driver circuit shorted to ground, driver circuit shorted to battery, driver circuits shorted together, failed PCM or shorted IAC motor.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
5. Start engine. Allow engine to run until operating temperature is reached. Using scan tool, actuate IAC motor wiggle test. Idle speed should raise and lower with scan tool display. If IAC motor operates properly, go to next step. If IAC motor does not operate properly, go to step 7).
6. Wiggle wiring harness from IAC motor to Powertrain Control Motor (PCM). If IAC motor stopped operating at any time, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If IAC motor did not stop operating at any time, stop IAC motor wiggle test. See INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. NOTE: For remaining test steps, see IAC DRIVER IDENTIFICATION table for IAC motor wire color identification.
7. Using scan tool, stop all actuation tests. With engine still running, disconnect IAC motor connector. Using a voltmeter, check voltage on IAC motor connector driver No. 1 wire. If voltage is more than 5 volts at any time, go to next step. If voltage is 5 volts or less at any time, go to TEST TC-25B.
8. Check voltage on IAC motor connector driver No. 2 wire. If voltage is more than 5 volts at any time, go to next step. If voltage is 5 volts or less at any time, go to TEST TC-25C.
9. Check voltage on IAC motor connector driver No. 3 wire. If voltage is more than 5 volts at any time, go to next step. If voltage is 5 volts or less at any time, go to TEST TC-25D.
10. Check voltage on IAC motor connector driver No. 4 wire. If voltage is more than 5 volts at any time, go to next step. If voltage is 5 volts or less at any time, go to TEST TC-25E.
11. Turn ignition off. Using an ohmmeter, check resistance of IAC motor connector driver No. 1 wire. If resistance is less than 5 ohms, repair short to ground in driver No. 1 wire. Perform TEST VER-2A. If resistance is more than 5 ohms, go to next step.
12. Check resistance of IAC motor connector driver No. 2 wire. If resistance is less than 5 ohms, repair short to ground in driver No. 2 wire. Perform TEST VER-2A. If resistance is more than 5 ohms, go to next step.
13. Check resistance of IAC motor connector driver No. 3 wire. If resistance is less than 5 ohms, repair short to ground in driver No. 3 wire. Perform TEST VER-2A. If resistance is more than 5 ohms, go to next step.
14. Check resistance of IAC motor connector driver No. 4 wire. If resistance is less than 5 ohms, repair short to ground in driver No. 4 wire. Perform TEST VER-2A. If resistance is more than 5 ohms, go to next step.
15. Turn ignition off. Disconnect PCM connector. Inspect PCM connector for damaged or pushed out terminals. Repair as necessary. Perform TEST VER-2A. If connector is okay, go to next step.
16. Using an ohmmeter, check resistance between the following wires at IAC motor connector. Record resistance readings. IAC motor connector driver No. 1 and driver No. 2 IAC motor connector driver No. 1 and driver No. 3 IAC motor connector driver No. 1 and driver No. 4
17. If resistance between any 2 wires was less than 5 ohms, repair those wires for shorting together. Perform TEST VER-2A. If resistance between all pairs of wires was 5 ohms or more, go to next step.
18. Using an external ohmmeter, check resistance between the following wires at IAC motor connector. Record resistance readings. IAC motor connector driver No. 2 and driver No. 3 IAC motor connector driver No. 2 and driver No. 4
19. If resistance between any 2 wires was less than 5 ohms, repair those wires for shorting together. Perform TEST VER-2A. If resistance between all pairs of wires was 5 ohms or more, go to next step.
20. Using an ohmmeter, check resistance between the following wires at IAC motor connector. Record resistance readings. IAC motor connector driver No. 3 and driver No. 4
21. If resistance between wires was less than 5 ohms, repair wires for shorting together. Perform TEST VER-2A. If resistance between wires was 5 ohms or more, replace IAC motor. Perform TEST VER-2A.

IAC DRIVER IDENTIFICATION

TEST TC-25B - IDLE AIR CONTROL MOTOR CIRCUITS

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for damaged or pushed out terminals. Repair as necessary. Perform TEST VER-2A. If PCM connector terminals are okay, go to next step. NOTE: For next step, see IAC DRIVER IDENTIFICATION table for IAC motor wire color identification.
2. Using an ohmmeter, check resistance of IAC motor driver No. 1 wire between IAC motor connector and PCM connector terminal No. 48. If resistance is 5 ohms or more, repair open in IAC motor driver No. 1 wire. Perform TEST VER-2A. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A.

IAC DRIVER IDENTIFICATION

TEST TC-25C - IDLE AIR CONTROL MOTOR CIRCUITS

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for damaged or pushed out terminals. Repair as necessary. Perform TEST VER-2A. If PCM connector terminals are okay, go to next step. NOTE: For next step, see IAC DRIVER IDENTIFICATION table for IAC motor wire color identification.
2. Using an ohmmeter, check resistance of IAC motor driver No. 2 wire between IAC motor connector and PCM connector terminal No. 49. If resistance is 5 ohms or more, repair open in IAC motor driver No. 2 wire. Perform TEST VER-2A. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A.

IAC DRIVER IDENTIFICATION

TEST TC-25D - IDLE AIR CONTROL MOTOR CIRCUITS

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for damaged or pushed out terminals. Repair as necessary. Perform TEST VER-2A. If PCM connector terminals are okay, go to next step. NOTE: For next step, see IAC DRIVER IDENTIFICATION table for IAC motor wire color identification.
2. Using an ohmmeter, check resistance of IAC motor driver No. 3 wire between IAC motor connector and PCM connector terminal No. 57. If resistance is 5 ohms or more, repair open in IAC motor driver No. 3 wire. Perform TEST VER-2A. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A.

IAC DRIVER IDENTIFICATION

TEST TC-25E - IDLE AIR CONTROL MOTOR CIRCUITS

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for damaged or pushed out terminals. Repair as necessary. Perform TEST VER-2A. If PCM connector terminals are okay, go to next step. NOTE: For next step, see IAC DRIVER IDENTIFICATION table for IAC motor wire color identification.
2. Using an ohmmeter, check resistance of IAC motor driver No. 4 wire between IAC motor connector and PCM connector terminal No. 58. If resistance is 5 ohms or more, repair open in IAC motor driver No. 4 wire. Perform TEST VER-2A. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A.

IAC DRIVER IDENTIFICATION

TEST TC-26A - THROTTLE POSITION SENSOR VOLTAGE LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition on with engine off. Using scan tool, read Throttle Position (TP) sensor voltage. If TP sensor voltage is less than .2 volt, go to step 6). If TP sensor voltage is .2 volt or more, go to next step.
2. While monitoring scan tool display, slowly open and close throttle. If voltage change is smooth, go to next step. If voltage change is not smooth, replace TP sensor. Perform TEST VER-2A.
3. Stop moving throttle. While monitoring scan tool display, wiggle TP sensor wiring harness. If voltage changes when wiggling TP sensor harness, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change when wiggling TP sensor harness, go to next step.
4. Condition to set trouble code is not present at this time. THROTTLE POSITION SENSOR VOLTAGE LOW DTC sets if Powertrain Control Module (PCM) terminal No. 35 is less than .2 volt for .704 second or vehicle speed is more than 20 MPH, engine speed is more than 1500 RPM, and engine vacuum is less than 2 in. Hg with TP sensor voltage less than .5 volt for .704 second. Possible causes are: TP sensor signal is shorted to ground, TP sensor failure, loss of 5-volt supply or PCM failure. Go to next step.
5. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, problem is not present at this time. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
6. Disconnect TP sensor connector. Using a voltmeter, check voltage on TP sensor 5-volt supply circuit at TP sensor connector. See TP SENSOR WIRE IDENTIFICATION table. TP SENSOR WIRE IDENTIFICATION Application Wire Color TP Sensor 5-Volt Supply Circuit Dark Green/Yellow TP Sensor Signal Circuit Brown/Red TP Sensor Ground Circuit Black/Dark Green
7. If voltage is 4 volts or more, go to next step. If voltage is less than 4 volts, repair open TP sensor 5-volt supply circuit. Perform TEST VER-2A.
8. Using scan tool, read TP sensor voltage. If voltage is one volt or less, go to next step. If voltage is more than one volt, replace TP sensor. Perform TEST VER-2A.
9. Turn ignition off. Disconnect Transmission Control Module (TCM) connector. Turn ignition on. Using scan tool, read TP sensor voltage. If voltage is one volt or less, go to next step. If voltage is more than one volt, replace TCM. Perform TEST VER-2A.
10. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of TP sensor signal circuit at TP sensor connector. See TP SENSOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on TP sensor signal circuit. Perform TEST VER-2A.
11. Using an ohmmeter, check resistance between TP sensor signal circuit and ground circuit at TP sensor connector. See TP SENSOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, repair TP sensor signal circuit for a short to TP sensor ground circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

TEST TC-27A - THROTTLE POSITION SENSOR VOLTAGE HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition on with engine off. Using scan tool, read Throttle Position (TP) sensor voltage. If TP sensor voltage is more than 4.5 volts, go to step 6). If TP sensor voltage is 4.5 volts or less, go to next step.
2. While monitoring scan tool display, slowly open and close throttle. If voltage change is smooth, go to next step. If voltage change is not smooth, replace TP sensor. Perform TEST VER-2A.
3. Stop moving throttle. While monitoring scan tool display, wiggle TP sensor wiring harness. If voltage changes when wiggling TP sensor harness, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change when wiggling TP sensor harness, go to next step.
4. Condition to set trouble code is not present at this time. THROTTLE POSITION SENSOR VOLTAGE HIGH DTC sets if Powertrain Control Module (PCM) terminal No. 35 is more than 4.5 volts for .704 seconds. Possible causes are: TP sensor signal is open, TP sensor failure, TP sensor ground circuit open or PCM failure. Go to next step.
5. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, problem is not present at this time. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
6. Disconnect TP sensor connector. Using a voltmeter, check voltage on TP sensor signal circuit at TP sensor connector. See TP SENSOR WIRE IDENTIFICATION table. If voltage is 10 volts or less, go to next step. If voltage is more than 10 volts, repair short to voltage on TP sensor signal circuit. Perform TEST VER-2A.
7. Connect a jumper wire between TP sensor connector signal circuit and ground circuit. See TP SENSOR WIRE IDENTIFICATION table. Using scan tool, read TP sensor voltage. If scan tool displays one volt or more, go to next step. If scan tool displays less than one volt, replace TP sensor. Perform TEST VER-2A. TP SENSOR WIRE IDENTIFICATION Application Wire Color TP Sensor 5-Volt Supply Circuit Dark Green/Yellow TP Sensor Signal Circuit Brown/Red TP Sensor Ground Circuit Black/Dark Green
8. Move jumper wire from TP sensor connector ground circuit to engine ground. Using scan tool, read TP sensor voltage. If voltage is one volt or more, go to next step. If voltage is less than one volt, repair open TP sensor ground circuit. Perform TEST VER-2A.
9. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of TP sensor signal circuit between TP sensor connector and ground. See TP SENSOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair TP sensor signal circuit for a short to 5-volt supply circuit. Perform TEST VER-2A.
10. Using an ohmmeter, check resistance of TP sensor signal circuit between TP sensor connector and PCM connector terminal No. 35. See TP SENSOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open TP sensor signal circuit. Perform TEST VER-2A.

TEST TC-30A - ECT TEMPERATURE SENSOR VOLTAGE TOO LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. A severe overheating condition could cause this DTC to set. Using scan tool, read Engine Coolant Temperature (ECT) sensor voltage. If voltage is .5 volt or more, go to next step. If voltage is less than .5 volt, go to step 5).
2. While monitoring scan tool display, wiggle ECT sensor wiring harness. If voltage changes when wiggling ECT sensor harness, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change when wiggling ECT sensor harness, go to next step.
3. Condition to set trouble code is not present at this time. ECT SENSOR VOLTAGE TOO LOW DTC sets if Powertrain Control Module (PCM) terminal No. 26 is less than .5 volt for more than 3 seconds. Possible causes are: ECT sensor signal circuit shorted to ground, ECT sensor shorted internally or PCM failure. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
5. Disconnect ECT sensor connector. Using scan tool, read ECT sensor voltage. If voltage is 4 volts or less, go to next step. If voltage is more than 4 volts, replace ECT sensor. Perform TEST VER-2A.
6. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of ECT sensor connector signal circuit. See ECT SENSOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on ECT sensor signal circuit. Perform TEST VER-2A.
7. Using an ohmmeter, check resistance between ECT sensor signal circuit and ECT sensor ground circuit on ECT sensor connector. See ECT SENSOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, repair ECT sensor signal circuit for a short to ECT sensor ground circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

ECT SENSOR WIRE IDENTIFICATION

TEST TC-31A - ECT SENSOR VOLTAGE TOO HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, read Engine Coolant Temperature (ECT) sensor voltage. If voltage is 4.5 volts or less, go to next step. If voltage is more than 4.5 volts, go to step 5 .
2. While monitoring scan tool display, wiggle ECT sensor wiring harness. If voltage changes when wiggling ECT sensor harness, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change when wiggling ECT sensor harness, go to next step.
3. Condition to set trouble code is not present at this time. ECT SENSOR VOLTAGE TOO HIGH DTC sets if Powertrain Control Module (PCM) terminal No. 26 is more than 4.9 volts for more than 3 seconds. Possible causes are: ECT sensor signal circuit open, ECT sensor open internally, ECT sensor ground circuit open or PCM failure. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
5. Disconnect ECT sensor connector. Connect a jumper wire between ECT sensor connector signal circuit and ground circuit. See ECT SENSOR WIRE IDENTIFICATION table. Using scan tool, read ECT sensor voltage. If voltage is one volt or more, go to next step. If voltage is less than one volt, replace ECT sensor. Perform TEST VER-2A. ECT SENSOR WIRE IDENTIFICATION Application Wire Color ECT Sensor Signal Circuit Dark Green/White ECT Sensor Ground Circuit Black/Dark Green
6. Move jumper wire from ECT sensor connector ground circuit to engine ground. Using scan tool, read ECT sensor voltage. If voltage is one volt or more, go to next step. If voltage is less than one volt, repair open ECT sensor ground circuit. Perform TEST VER-2A.
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of ECT sensor signal circuit between ECT sensor connector and PCM connector terminal No. 26. See ECT SENSOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open ECT sensor signal circuit. Perform TEST VER-2A.

TEST TC-32A - O2 SENSOR 1/1 STAYS AT CENTER

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/1 IDENTIFICATION table. Start engine and allow it to reach operating temperature. Using scan tool, set engine speed to 1500 RPM. Using scan tool, read O2S 1/1 state. If O2S 1/1 state is switching, go to next step. If O2S 1/1 state is not switching, go to step 4). O2 SENSOR 1/1 IDENTIFICATION Application Location 2.5L Rear Bank Upstream O2S
2. While monitoring scan tool display, wiggle O2S wiring harness. If O2S 1/1 state was locked at center at any time while wiggling wiring harness, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-5A. If O2S 1/1 state was not locked at center at any time while wiggling wiring harness, go to next step.
3. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, test is complete. Perform TEST VER-5A. If related wiring and connectors were repaired, perform TEST VER-5A.
4. Turn ignition on with engine off. Disconnect O2S 1/1 connector. Inspect wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If wiring and connectors were repaired, perform TEST VER-5A.
5. Using an ohmmeter, check resistance on O2S 1/1 sensor connector (harness side) sensor ground circuit. See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open O2S1/1 sensor ground circuit. Perform TEST VER-5A. O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) Application Wire Color O2S 1/1 Sensor Signal Circuit White/Black O2S 1/1 Sensor Ground Circuit Black/Dark Green
6. Connect a jumper wire between O2S 1/1 connector (harness side) signal circuit and battery voltage. See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. Using scan tool, read O2S 1/1 voltage. If voltage is one volt or less, go to next step. If voltage is more than one volt, replace O2S 1/1. Perform TEST VER-5A.
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Disconnect jumper wire from O2S 1/1 connector. Using an ohmmeter, check resistance of O2S 1/1 sensor signal circuit between O2S 1/1 connector and PCM terminal No. 30. See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-5A. If resistance is 5 ohms or more, repair open O2S 1/1 signal ground circuit. Perform TEST VER-5A.

TEST TC-35A - NO VEHICLE SPEED SENSOR SIGNAL

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Raise and support vehicle under lower control arms, allowing drive wheels to spin free. Start engine. Using scan tool, read Vehicle Speed Sensor (VSS). Put transmission in any forward gear. If scan tool displays more than zero MPH, go to next step. If scan tool does not display more than zero MPH, go to step 5).
2. Condition to set trouble code is not present at this time. NO VEHICLE SPEED SENSOR SIGNAL DTC sets if no signal from Vehicle Speed Sensor (VSS) signal is present from Transmission Control Module (TCM) for more than 11 seconds. If vehicle is NOT equipped with a 4-speed automatic transmission, go to next step. If vehicle is equipped with a 4-speed automatic transmission, possible causes are: open or shorted signal circuit, speedometer pinion factor not programmed, output speed sensor circuit problem, failed Powertrain Control Module (PCM) or failed TCM. Go to step 4).
3. Possible causes are: open or shorted signal circuit, speedometer pinion damaged, open 8-volt supply circuit, open sensor ground circuit, failed VSS or failed Powertrain Control Module (PCM). Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
5. If vehicle is equipped with a 4-speed automatic transmission, go to next step. If vehicle is not equipped with a 4-speed automatic transmission, go to TEST TC-35B.
6. Using scan tool, read transmission trouble codes. If transmission Diagnostic Trouble Codes (DTCs) 50-58 are present or pinion factor is not programmed, repair transmission as required. If transmission Diagnostic Trouble Codes (DTCs) 50-58 are not present or pinion factor is programmed, go to next step.
7. Turn ignition off. Disconnect Transmission Control Module (TCM) connector. Connect one end of a jumper wire to TCM connector terminal No. 58 Yellow/White wire. Turn ignition on. Using scan tool, read VSS signal. While observing scan tool display, tap other end of jumper wire to ground. If scan tool does not display more than zero MPH, go to next step. If scan tool displays more than zero MPH, repair transmission as required.
8. Turn ignition off. Disconnect PCM connector. Using an ohmmeter, check resistance of VSS signal circuit Yellow/White wire between PCM connector terminal No. 66 and TCM connector terminal No. 58. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open VSS signal circuit. Perform TEST VER-2A.
9. Using an ohmmeter, check resistance of VSS signal circuit at TCM connector terminal No. 58 White/Yellow wire. If resistance is less than 5 ohms, repair short to ground on VSS signal circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

TEST TC-35B - NO VEHICLE SPEED SENSOR SIGNAL

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect 3-pin Vehicle Speed Sensor (VSS) connector. Turn ignition on. Using a voltmeter, check voltage on VSS connector 8-volt power supply circuit Yellow wire. If voltage is more than 7 volts, go to next step. If voltage is 7 volts or less, repair open 8-volt power supply circuit. Perform TEST VER-2A.
2. Using a voltmeter, check voltage on VSS connector signal circuit Yellow/White wire. If voltage is more than 4 volts, go to next step. If voltage is 4 volts or less, go to step 5).
3. Connect a jumper wire to VSS connector signal circuit Yellow/White wire. Using scan tool, read VSS signal. While observing scan tool, tap other end of jumper wire to VSS connector ground circuit Black/Dark Green wire. If scan tool displays more than zero MPH, go to next step. If scan tool does not display more than zero MPH, go to TEST TC-35C.
4. Remove VSS sensor from transmission. Inspect speedometer pinion gear. If speedometer pinion gear is okay, replace VSS. Perform TEST VER-2A. If speedometer pinion gear is not okay, repair or replace as necessary. Perform TEST VER-2A.
5. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of VSS signal circuit between VSS connector and PCM connector terminal No. 66 Yellow/White wire. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open VSS signal circuit. Perform TEST VER-2A.
6. Using an ohmmeter, check VSS signal circuit at PCM connector terminal No. 66 Yellow/White wire. If resistance is less than 5 ohms, repair short to ground in VSS signal circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

TEST TC-35C - NO VEHICLE SPEED SENSOR SIGNAL

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Using an ohmmeter, check resistance on VSS connector ground circuit Black/Dark Green wire. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open VSS ground circuit. Perform TEST VER-2A.
2. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for pushed out or damaged terminals. Repair PCM connector as necessary. Perform TEST VER-2A. If PCM connector is okay, go to next step.
3. Using an ohmmeter, check resistance of VSS signal circuit between VSS connector and PCM connector terminal No. 66 Yellow/White wire. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open VSS signal circuit. Perform TEST VER-2A.

TEST TC-36A - MAP SENSOR VOLTAGE TOO LOW OR NO 5 VOLTS TO MAP SENSOR

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. With engine off, using scan tool, read Manifold Absolute Pressure (MAP) sensor voltage. If MAP sensor voltage is less than .2 volt, go to step 7). If MAP sensor voltage is .2 volt or more, go to next step.
2. Start engine. Using scan tool, read MAP sensor voltage. If MAP sensor is less than .2 volt, go to step 7). If MAP sensor voltage is .2 volt or more, go to next step.
3. Turn ignition on with engine off. Using scan tool, read MAP sensor voltage. If MAP sensor voltage is less than 1.2 volts, go to step 7). If MAP sensor voltage voltage is 1.2 volts or more, go to next step.
4. Start engine. While monitoring scan tool display, wiggle MAP sensor wiring harness. If voltage changes when wiggling MAP sensor harness, repair wiring harness as necessary where wiggling caused voltage to change. Perform TEST VER-2A. If voltage did not change when wiggling TP sensor harness, go to next step.
5. Condition to set trouble code is not present at this time. MAP SENSOR VOLTAGE TOO LOW or NO 5 VOLTS TO MAP SENSOR DTC sets if MAP sensor signal voltage is less than 1.2 volts at engine start or less than .2 volt for 1.76 seconds with engine running. Possible causes are: open 5-volt supply circuit, signal circuit shorted to ground, failed MAP sensor or PCM failure. Go to next step.
6. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
7. Turn ignition off. Disconnect MAP sensor electrical connector. Turn ignition on. Using scan tool, read MAP sensor voltage. If MAP sensor voltage is 4 volts or less, go to next step. If MAP sensor voltage is more than 4 volts, replace MAP sensor. Perform TEST VER-2A.
8. Using a voltmeter, check voltage on MAP sensor connector 5-volt supply circuit. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is 4 volts or more, go to next step. If voltage is less than 4 volts, repair open 5-volt supply circuit. Perform TEST VER-2A. MAP SENSOR CONNECTOR WIRE IDENTIFICATION Application Wire Color MAP Sensor 5-Volt Supply Circuit Dark Green/Yellow MAP Sensor Signal Circuit Yellow/Black MAP Sensor Ground Circuit Black/Dark Green
9. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance between MAP sensor signal circuit and MAP sensor ground circuit on MAP sensor connector. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair MAP sensor signal circuit for a short to MAP sensor ground circuit. Perform TEST VER-2A.
10. Using an ohmmeter, check resistance of MAP sensor signal circuit at MAP sensor connector. If resistance is less than 5 ohms, repair short to ground in MAP sensor signal circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

TEST TC-37A - MAP SENSOR VOLTAGE TOO HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. With engine off, using scan tool, read MAP sensor voltage. If MAP sensor voltage is more than 4.6 volts go to step 5). If MAP sensor voltage is 4.6 volts or less, go to next step.
2. Start engine. While monitoring scan tool display, wiggle MAP sensor wiring harness. If voltage changes when wiggling MAP sensor harness, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change when wiggling MAP sensor harness, go to next step.
3. Condition to set trouble code is not present at this time. MAP SENSOR VOLTAGE TOO HIGH DTC sets if MAP sensor signal voltage is more than 4.6 volts at start or with engine running for 1.76 seconds. Possible causes are: MAP sensor signal is open, MAP sensor open internally, MAP sensor ground circuit open, MAP sensor signal circuit shorted to voltage or PCM failure. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
5. Turn ignition off. Disconnect MAP sensor electrical connector. Turn ignition on (MAP sensor voltage only updates when ignition is cycled off and on). Using a voltmeter, check voltage of MAP sensor signal circuit at MAP sensor connector. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is 5 volts or less, go to next step. If voltage is more than 5 volts, repair short to voltage on MAP sensor signal circuit. Perform TEST VER-2A.
6. Turn ignition off. Connect a jumper wire between MAP sensor signal circuit and MAP sensor ground circuit at MAP sensor connector. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. Turn ignition on. Using scan tool read MAP sensor voltage. If scan tool displays one volt or more, go to next step. If scan tool displays less than one volt, replace MAP sensor. Perform TEST VER-2A. MAP SENSOR CONNECTOR WIRE IDENTIFICATION Application Wire Color MAP Sensor 5-Volt Supply Circuit Dark Green/Yellow MAP Sensor Signal Circuit Yellow/Black MAP Sensor Ground Circuit Black/Dark Green
7. Turn ignition off. Move jumper wire from MAP sensor ground circuit to engine ground. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. Turn ignition on. Using scan tool, read MAP sensor voltage. If MAP sensor voltage is one volt or more, go to next step. If voltage is less than one volt, repair open MAP sensor ground circuit. Perform TEST VER-2A.
8. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of MAP sensor signal circuit between MAP sensor connector and PCM connector terminal No. 36. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open MAP sensor signal circuit. Perform TEST VER-2A.

TEST TC-39A - NO CHANGE IN MAP SENSOR FROM START TO RUN

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition on with engine off. Using scan tool, read Diagnostic Trouble Codes (DTCs). If MAP SENSOR VOLTAGE TOO LOW DTC is set, go to TEST TC-36A. If MAP SENSOR VOLTAGE TOO LOW DTC is not set, go to next step.
2. Start engine. Allow engine to idle for 30 seconds. Using scan tool, read DTCs. If scan tool displays NO CHANGE IN MAP FROM START TO RUN with a start run count of zero, go to step 7). If scan tool does not display NO CHANGE IN MAP FROM START TO RUN with a start run count of zero, go to next step.
3. Using scan tool, set engine speed to 1500 RPM. Using scan tool, read MAP sensor voltage. While monitoring scan tool display, wiggle MAP sensor wiring harness from MAP sensor to PCM. If engine stalls or voltage becomes erratic, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If engine did not stall or voltage did not become erratic, go to next step.
4. While observing scan tool display, snap throttle open and closed. If vacuum did not rapidly drop to less than one in. Hg, go to step 6). If vacuum rapidly dropped to less than one in. Hg, go to next step.
5. Condition to set trouble code is not present at this time. NO CHANGE IN MAP FROM START TO RUN DTC sets if too small a difference is seen between barometric pressure at ignition on and manifold vacuum with engine running for 1.76 seconds. Possible causes are: restricted or leaking vacuum/pressure to MAP sensor, ice in MAP sensor or MAP sensor passage, failed MAP sensor or Powertrain Control Module (PCM) failure. Test is complete, perform TEST VER-2A.
6. Inspect condition of intake manifold and MAP sensor vacuum ports. If a restriction or defect is found in vacuum ports, repair restricted or defective vacuum ports as necessary. Perform TEST VER-2A. If no restrictions or defects are found in vacuum ports, replace MAP sensor. Perform TEST VER-2A.
7. Turn ignition on with engine off. Remove MAP sensor and inspect for vacuum restrictions. If a restriction is not found, go to next step. If a restriction is found, remove restriction and install MAP sensor. Perform TEST VER-2A.
8. Using a voltmeter, check voltage on MAP sensor connector 5-volt supply circuit. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 4 volts, replace MAP sensor. Perform TEST VER-2A. If voltage is 4 volts or less, repair open 5-volt supply circuit. Perform TEST VER-2A.

MAP SENSOR CONNECTOR WIRE IDENTIFICATION

TEST TC-40A - NO CRANK REFERENCE SIGNAL AT PCM

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Scheme 94

1. Turn ignition off, then turn ignition on. Attempt to start engine. Using scan tool, read camshaft signal state and crankshaft signal state while attempting to start engine. Go to next step.
2. If either signal state changed to present, go to next step. If either signal state did not change to present, go to step 6).
3. If only camshaft signal state changed, go to step 6). If only crankshaft signal state changed, go to TEST TC-1A. If both camshaft signal state and crankshaft signal state changed to present, go to next step.
4. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
5. If engine is not started, start engine. Wiggle wiring harness between Camshaft Position (CMP) sensor and Crankshaft Position (CKP) sensor to Powertrain Control Module (PCM). If engine misses or stalls, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If engine did not miss or stall, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
6. Turn ignition off. Disconnect Crankshaft Position (CKP) sensor connector. (Scheme 94) Turn ignition on. Using a voltmeter, check voltage on CKP sensor connector 8-volt supply circuit. See CKP SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 7 volts, go to next step. If voltage is 7 volts or less, go to TEST TC-40B. (Scheme 94): Identifying Crankshaft Position (CKP) Sensor Location CKP SENSOR CONNECTOR WIRE IDENTIFICATION Application Wire Color CKP Sensor 8-Volt Supply Circuit Yellow CKP Sensor Signal Circuit Dark Blue/White CKP Sensor Ground Circuit Black/Dark Green
7. Turn ignition off. Connect one end of a jumper wire to CKP sensor connector (harness side) signal circuit. Turn ignition on. Using scan tool, monitor CKP sensor state. While observing scan tool display, tap end of jumper wire to CKP sensor connector (harness side) ground circuit several times. If CKP sensor state did not change to present, go to next step. If CKP sensor state changed to present, go to TEST TC-40C.
8. Turn ignition off. Remove jumper wire. Using an ohmmeter, check resistance of CKP sensor connector (harness side) ground circuit. See CKP SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open CKP sensor ground circuit. Perform TEST VER-2A.
9. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of CKP sensor signal circuit between CKP sensor connector (harness side) and PCM connector terminal No. 32. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open CKP sensor signal circuit. Perform TEST VER-2A.
10. Using an ohmmeter, check resistance of CKP sensor signal circuit at CKP sensor connector. If resistance is less than 5 ohms, repair short to ground in CKP sensor signal circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

TEST TC-40B - NO CRANK REFERENCE SIGNAL AT PCM

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect Camshaft Position (CMP) sensor connector. (Scheme 95), 117, 118, 119 or 120. Turn ignition on. Using a voltmeter, check voltage on Crankshaft Position (CKP) sensor connector (harness side) 8-volt supply circuit. If voltage is 7 volts or less, go to next step. If voltage is more than 7 volts, replace CMP sensor. Perform TEST VER-2A.
2. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance on CKP sensor connector (harness side) 8-volt supply circuit. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on CKP 8-volt supply circuit. See CKP SENSOR CONNECTOR WIRE IDENTIFICATION table. Perform TEST VER-2A.
3. Using an ohmmeter, check resistance of CKP sensor 8-volt supply circuit between CKP sensor (harness side) and PCM connector terminal No. 32. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open in CKP sensor 8-volt supply circuit. See CKP SENSOR CONNECTOR WIRE IDENTIFICATION table. Perform TEST VER-2A.

Identifying Camshaft Position (CMP) Sensor Location. Scheme 95

CKP SENSOR CONNECTOR WIRE IDENTIFICATION

TEST TC-40C - NO CRANK REFERENCE SIGNAL AT PCM

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Remove Crankshaft Position (CKP) Sensor. Inspect flywheel for damage. If flywheel is damaged, repair as necessary. Perform TEST VER-2A. If flywhell is not damaged, replace CKP sensor. Perform TEST VER-2A.

TEST TC-41A - IGNITION COIL NO. 3 PRIMARY CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect ignition coil connector. Inspect ignition coil connector for damaged, pushed out or miswired terminals. Repair ignition coil connector as necessary. Perform TEST VER-2A. If ignition coil connector is okay, go to next step.
2. Turn ignition on. Using scan tool, actuate ignition coil No. 3. Using a voltmeter, check voltage on ignition coil connector (harness side) ASD relay output circuit Dark Green/Orange wire. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open Dark Green/Orange wire. Perform TEST VER-2A.
3. Using an ohmmeter, check resistance between ignition coil No. 3 terminal and battery voltage terminal on ignition coil pins. (Scheme 96) If resistance is less than 2 ohms, go to next step. If resistance is 2 ohms or more, replace ignition coil. Perform TEST VER-2A.
4. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of ignition coil No. 3 driver circuit Red wire on ignition coil connector (harness side). If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on ignition coil No. 3 driver circuit. Perform TEST VER-2A.
5. Using an ohmmeter, check resistance of ignition coil driver No. 3 circuit Red wire between ignition coil connector and PCM connector terminal No. 2. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open ignition coil driver No. 3 circuit. Perform TEST VER-2A.

Identifying Ignition Coil Pins. Scheme 96

TEST TC-42A - IGNITION COIL NO. 2 PRIMARY CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect ignition coil connector. Inspect ignition coil connector for damaged, pushed out or miswired terminals. Repair ignition coil connector as necessary. Perform TEST VER-2A. If ignition coil connector is okay, go to next step.
2. Turn ignition on. Using scan tool, actuate ignition coil No. 2. Using a voltmeter, check voltage on ignition coil connector (harness side) ASD relay output circuit. See IGNITION COIL CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-2A. IGNITION COIL CONNECTOR WIRE IDENTIFICATION Application Wire Color Ignition Coil ASD Relay Output Circuit Black/Red Ignition Coil No. 2 Driver Circuit Brown
3. Using an ohmmeter, check resistance between ignition coil No. 2 terminal and battery voltage terminal on ignition coil pins. See1) Turn ignition off. Disconnect ignition coil connector. Inspect ignition coil connector for damaged, pushed out or miswired terminals. Repair ignition coil connector as necessary. Perform TEST VER-2A. If ignition coil connector is okay, go to next step.
4. Turn ignition on. Using scan tool, actuate ignition coil No. 2. Using a voltmeter, check voltage on ignition coil connector (harness side) ASD relay output circuit. See IGNITION COIL CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-2A. IGNITION COIL CONNECTOR WIRE IDENTIFICATION Application Wire Color Ignition Coil ASD Relay Output Circuit Black/Red Ignition Coil No. 2 Driver Circuit Brown
5. Using an ohmmeter, check resistance between ignition coil No. 2 terminal and battery voltage terminal on ignition coil pins. (Scheme 97)or 123. If resistance is less than 2 ohms, go to next step. If resistance is 2 ohms or more, replace ignition coil. Perform TEST VER-2A.
6. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of ignition coil No. 2 driver circuit on ignition coil connector (harness side). See IGNITION COIL CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on ignition coil No. 2 driver circuit. Perform TEST VER-2A.
7. Using an ohmmeter, check resistance of ignition coil No. 2 driver circuit between ignition coil connector and PCM connector terminal No. 3. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open ignition coil driver No. 2 circuit. Perform TEST VER-2A.

Identifying Ignition Coil Pins. Scheme 97

TEST TC-43A - IGNITION COIL NO. 1 PRIMARY CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Before proceeding with this test, repair any ASD relay trouble codes. Using scan tool, erase trouble codes. Attempt to start engine. Crank engine for 10 seconds if necessary. Using scan tool, read trouble codes. If scan tool does not display any ignition coil trouble code, go to next step. If scan tool displays IGNITION COIL #1 PRIMARY CIRCUIT, go to step 4). If scan tool displays IGNITION COIL #2 PRIMARY CIRCUIT, go to TEST TC-42A. If scan tool displays IGNITION COIL #3 PRIMARY CIRCUIT, go to TEST 121.
2. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
3. Start engine. Wiggle wiring harness between ignition coil and Powertrain Control Module (PCM). If engine misses or stalls, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If engine did not miss or stall, test is complete. Perform TEST VER-2A.
4. If vehicle is equipped with a 2.5L engine, go to step 9). If vehicle is not equipped with a 2.5L engine, turn ignition off. Disconnect ignition coil connector. Inspect ignition coil connector for damaged, pushed out or miswired terminals. Repair ignition coil connector as necessary. Perform TEST VER-2A. If ignition coil connector is okay, go to next step.
5. Turn ignition on. Using scan tool, actuate ignition coil No. 1. Using a voltmeter, check voltage on ignition coil connector (harness side) ASD relay output circuit. See IGNITION COIL CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-2A. IGNITION COIL CONNECTOR WIRE IDENTIFICATION Application Wire Color Ignition Coil ASD Relay Output Circuit Black/Red Ignition Coil No. 1 Driver Circuit Black/Dark Blue Ignition Coil No. 2 Driver Circuit Brown
6. Using an ohmmeter, check resistance between ignition coil No. 1 terminal and battery voltage terminal on ignition coil pins. see scheme 45 If resistance is less than 2 ohms, go to next step. If resistance is 2 ohms or more, replace ignition coil. Perform TEST VER-2A. see scheme 45: Identifying Ignition Coil Pins
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of ignition coil No. 1 driver circuit on ignition coil connector (harness side). See IGNITION COIL CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on ignition coil No. 1 driver circuit. Perform TEST VER-2A.
8. Using an ohmmeter, check resistance of ignition coil No. 1 driver circuit between ignition coil connector and PCM connector terminal No. 2. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open ignition coil driver No. 1 circuit. Perform TEST VER-2A.
9. Disconnect distributor 2-pin connector. Turn ignition on. Using scan tool, actuate ignition coil No. 1. Using a voltmeter, check voltage on distributor connector (harness side) ASD relay output circuit Black/Red wire. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay circuit. Perform TEST VER-2A.
10. Disconnect distributor 6-pin connector. Scan tool should still be actuating ignition coil No. 1. Using an analog voltmeter, check voltage on distributor 6-pin connector ignition coil driver circuit Red/Dark Green wire. If voltage toggles between zero and one volt, replace ignition coil. Perform TEST VER-2A. If voltage does not toggle between zero and one volt, go to next step.
11. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on ignition coil driver circuit. Perform TEST VER-2A.
12. Using an ohmmeter, check resistance of ignition coil driver circuit between distributor 6-pin connector and PCM connector terminal No. 11. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A. If resistance is less than 5 ohms, repair open ignition coil driver circuit. Perform TEST VER-2A.

TEST TC-44A - NO ASD RELAY OUTPUT VOLTAGE AT PCM

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. If AUTO SHUTDOWN RELAY CONTROL CIRCUIT DTC is also set, go to TEST TC-10A. If trouble code AUTO SHUTDOWN RELAY CONTROL CIRCUIT is not set, go to next step.
2. Using scan tool, erase trouble codes. Start engine. Allow engine to idle for at least 10 seconds. Using scan tool, read DTCs. If scan tool displays NO ASD RELAY OUTPUT VOLTAGE AT PCM with a start run count of zero, go to step 6). If scan tool does not display NO CHANGE IN MAP FROM START TO RUN with a start run count of zero, go to next step.
3. Condition to set trouble code is not present at this time. NO ASD RELAY OUTPUT VOLTAGE AT PCM DTC sets if no voltage is sensed at PCM when ASD relay is energized. Possible causes are: ASD relay output circuit open, fused B+ circuit open, faulty ASD relay or PCM failure. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
5. Using scan tool, erase trouble codes. Start engine. Wiggle wiring harness between ASD relay and PCM. If wiggling caused trouble code to appear, repair wiring harness as necessary where wiggling caused problem. Perform TEST VER-2A. If wiggling did not cause trouble code to appear, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
6. Attempt to start engine. If engine did not start, go to next step. If engine started, go to step 10).
7. Disconnect ASD relay. Using a voltmeter, check voltage on ASD relay connector fused battery voltage circuit. See ASD RELAY CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused battery voltage circuit. Perform TEST VER-2A.
8. Install a substitute ASD relay. Attempt to start vehicle. If engine does not start, go to next step. If engine started, replace original ASD relay. Perform TEST VER-2A.
9. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of ASD relay output circuit between ASD relay connector and PCM connector terminal No. 6. See ASD RELAY CONNECTOR WIRE IDENTIFICATION table. If resistance is more than 5 ohms, repair open ASD relay output circuit. Perform TEST VER-2A. If resistance is 5 ohms or less, replace PCM. Perform TEST VER-2A.
10. Turn ignition off. Disconnect PCM connector. Disconnect ASD relay. Using an ohmmeter, check resistance of ASD relay output circuit between ASD relay connector and PCM connector terminal No. 6. See ASD RELAY CONNECTOR WIRE IDENTIFICATION table. If resistance is more than 5 ohms, repair open ASD relay output circuit. Perform TEST VER-2A. If resistance is 5 ohms or less, replace PCM. Perform TEST VER-2A.

ASD RELAY CONNECTOR WIRE IDENTIFICATION

TEST TC-46A - EGR SYSTEM FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn off all accessories. Start engine. Allow engine to reach operating temperature. Disconnect Exhaust Gas Recirculation (EGR) solenoid electrical connector. Leave EGR solenoid electrical connector disconnected for remainder of test.
2. Disconnect vacuum supply hose from EGR solenoid. Connect a vacuum gauge to disconnected hose. If vacuum gauge indicates more than 10 in. Hg vacuum, go to next step. If vacuum gauge indicates 10 in. Hg vacuum or less, repair vacuum supply to EGR solenoid. Perform TEST VER-2A.
3. Record vacuum reading. Reconnect vacuum hose to EGR solenoid. Disconnect vacuum hose from EGR valve. Connect a vacuum gauge to disconnected hose. If vacuum gauge reading pulsates, go to next step. If vacuum gauge reading does not pulsate, go to step 6).
4. While observing vacuum gauge, momentarily raise engine speed to more than 2000 RPM. If vacuum gauge reading stabilized, go to next step. If vacuum gauge reading did not stabilize, replace EGR valve assembly. Perform TEST VER-2A.
5. Turn engine off. Remove EGR valve. Inspect manifold and tube for restrictions. If any restrictions were found, repair as necessary. Perform TEST VER-2A. If no restrictions were found, replace EGR valve assembly. Perform TEST VER-2A.
6. Reconnect hose to EGR valve. Disconnect backpressure hose from EGR transducer. Connect a pressure gauge to backpressure hose. If pressure gauge reading is not pulsating, go to next step. If pressure gauge reading is pulsating, replace EGR assembly.
7. Inspect exhaust system for a sizeable leak. If no leaks were found, go to next step. If any leaks were found, repair exhaust system as necessary. Perform TEST VER-2A.
8. Inspect EGR valve mounting area, EGR valve tightness and EGR valve gasket. Repair or replace EGR valve as necessary. Perform TEST VER-2A. If no repairs were necessary, replace EGR valve assembly. Perform TEST VER-2A.

TEST TC-48A - PCM FAILURE EEPROM WRITE DENIED & PCM FAILURE SRI MILE NOT STORED

1. Turn ignition on. Using scan tool, perform SRI memory test. If scan tool displays WRITE FAILURE, replace Powertrain Control Module (PCM). Perform TEST VER-2A. If scan tool does not display WRITE FAILURE, go to next step.
2. If scan tool displays WRITE REFUSED, go to step 5). If scan tool does not display WRITE REFUSED, go to next step.
3. If scan tool displays SRI MILEAGE INVALID, update mileage and retest SRI memory. Perform TEST VER-2A. If scan tool does not display SRI MILEAGE INVALID, go to next step.
4. Compare SRI mileage stored with instrument panel odometer. If mileage is the same, retest SRI memory. Perform TEST VER-2A. If mileage is not the same, update mileage and retest SRI memory. Perform TEST VER-2A.
5. PCM was busy. Using scan tool, perform SRI memory test. Retest SRI memory 2 more times if necessary. If scan tool displays WRITE REFUSED, replace PCM. If scan tool does not display WRITE REFUSED, test is complete. Perform TEST VER-2A.

TEST TC-57A - INTAKE AIR TEMPERATURE SENSOR VOLTAGE LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, read Intake Air Temperature (IAT) sensor voltage. If voltage is.5 volt or more, go to next step. If voltage is less than.5 volt, go to step 5).
2. Observe Intake Air Temperature (IAT) sensor voltage on scan tool. Wiggle wiring harness between IAT sensor and PCM. (Scheme 98)through 133. If voltage changes, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change, go to next step.
3. Condition to set trouble code is not present at this time. INTAKE AIR TEMP SENSOR VOLTAGE LOW DTC sets if IAT sensor circuit voltage on Powertrain Control Module (PCM) connector terminal No. 37 goes less than.157 volt. Possible causes are: IAT sensor signal circuit shorted to ground, IAT sensor internally shorted or PCM failure. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
5. Disconnect IAT sensor connector. (Scheme 98)through 133. Using scan tool, read IAT sensor voltage. If voltage is 4 volts or less, go to next step. If voltage is more than 4 volts, replace IAT sensor. Perform TEST VER-2A.
6. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance between IAT sensor signal circuit and IAT sensor ground circuit on IAT sensor connector. See IAT SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair IAT sensor signal circuit for a short to IAT sensor ground circuit. Perform TEST VER-2A. IAT SENSOR CONNECTOR WIRE IDENTIFICATION Application Wire Color IAT Sensor Signal Circuit Brown/Dark Blue IAT Sensor Ground Circuit Black/Dark Green
7. Using an ohmmeter, check resistance of IAT sensor signal circuit. See IAT SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, repair short to ground on IAT sensor signal circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

Identifying Intake Air Temperature (IAT) Sensor Location. Scheme 98

Identifying Intake Air Temperature (IAT) Sensor Location. Scheme 99

TEST TC-58A - INTAKE AIR TEMPERATURE SENSOR VOLTAGE HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, read Intake Air Temperature (IAT) sensor voltage. If voltage is 4.5 volts or less, go to next step. If voltage is more than 4.5 volts, go to step 5).
2. Observe Intake Air Temperature (IAT) sensor voltage on scan tool. Wiggle wiring harness between IAT sensor and PCM. see scheme 48 If voltage changes, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change, go to next step.
3. Condition to set trouble code is not present at this time. INTAKE AIR TEMP SENSOR VOLTAGE HIGH DTC sets if IAT sensor circuit voltage on Powertrain Control Module (PCM) connector terminal No. 37 goes more than 4.9 volts. Possible causes are: IAT sensor signal circuit open, IAT sensor internally open or PCM failure. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
5. Disconnect IAT sensor connector. see scheme 48 Using a voltmeter, check voltage of IAT sensor signal circuit. See IAT SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is 6 volts or less, go to next step. If voltage is more than 6 volts, repair short to voltage on IAT sensor signal circuit. Perform TEST VER-2A.
6. Connect a jumper wire between IAT sensor signal circuit and IAT sensor ground circuit on IAT sensor connector. Using scan tool, read IAT sensor voltage. If voltage is one volt or more, go to next step. If voltage is less than one volt, replace IAT sensor. Perform TEST VER-2A.
7. Move jumper wire from IAT sensor connector ground circuit to an engine ground. Using scan tool, read IAT sensor voltage. If voltage is one volt or more, go to next step. If voltage is less than one volt, repair open IAT sensor ground circuit. Perform TEST VER-2A.
8. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of IAT sensor signal circuit between IAT sensor connector and PCM connector terminal No. 37. See IAT SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, repair open IAT sensor signal circuit. Perform TEST VER-2A. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A.

IAT SENSOR CONNECTOR WIRE IDENTIFICATION

TEST TC-59A - KNOCK SENSOR CIRCUIT

Note. Test applies only to 3.3L (gasoline). For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.3L article.

1. Disconnect connector at knock sensor. Knock sensor is located on cylinder block, just in front of the starter.
2. Turn ignition on with engine off. Using voltmeter, check voltage at terminal No. 2 (Dark Blue/Light Green wire) on connector for knock sensor.
3. If voltage is 2 volts or less, go to next step. If voltage is more than 2 volts, repair short to voltage in Dark Blue/Light Green wire between PCM and knock sensor. Perform TEST VER-2A. The PCM is located between driver's side front fender and power distribution center, near battery.
4. Using ohmmeter, check resistance between ground and terminal No. 1 (Black/Light Blue wire) on connector for knock sensor. If resistance is 5 ohms or more, repair open circuit in Black/Light Blue wire between PCM and knock sensor. Perform TEST VER-2A. The PCM is located between driver's side front fender and power distribution center, near battery. If resistance is less than 5 ohms, go to next step.
5. Turn ignition off. Disconnect connectors from PCM. The PCM is located between driver's side front fender and power distribution center, near battery.
6. Using ohmmeter, check resistance between ground and terminal No. 2 (Dark Blue/Light Green wire) on connector for knock sensor. If resistance is less than 5 ohms, repair short to ground in Dark Blue/Light Green wire between PCM and knock sensor. Perform TEST VER-2A. If resistance is 5 ohms or more, go to next step.
7. Using ohmmeter, check resistance between terminal No. 2 (Dark Blue/Light Green wire) on connector for knock sensor and PCM connector terminal No. 24 (Dark Blue/Light Green wire). If resistance is less than 5 ohms, replace knock sensor. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open circuit in Dark Blue/Light Green wire between PCM and knock sensor. Perform TEST VER-2A.

TEST TC-60A - BAROMETRIC PRESSURE OUT OF RANGE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, read Manifold Absolute Pressure (MAP) sensor voltage. If voltage is 2.2 volts or more, go to next step. If voltage is less than 2.2 volts, go to step 7).
2. Condition to set trouble code is not present at this time. BAROMETRIC PRESSURE OUT OF RANGE DTC sets if MAP sensor circuit voltage on Powertrain Control Module (PCM) connector terminal No. 36 is less than 2.196 volts, but more than.019 volt for 300 milliseconds. Possible causes are: MAP sensor failure or PCM failure. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. Perform TEST VER-2A. If no problems were found with wiring and connectors, go to next step.
4. Observe MAP sensor voltage on scan tool. Wiggle wiring harness between MAP sensor and PCM. see scheme 49 If voltage goes less than 2.2 volts, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not go less than 2.2 volts at all, go to next step.
5. See INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
6. Disconnect MAP sensor connector. see scheme 49 Turn ignition off, then turn ignition on again. Using scan tool, read MAP sensor voltage. If voltage is 4.9 volts or less, go to next step. If voltage is more than 4.9 volts, replace MAP sensor. Perform TEST VER-2A.
7. If voltage is 2.2 volts or less, go to next step. If voltage is more than 2.2 volts, repair MAP sensor signal circuit for a partial short to ground. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. Perform TEST VER-2A.
8. Using a voltmeter, check voltage of MAP sensor 5-volt supply circuit. See IAT SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 4.5 volts, go to next step. If voltage is 4.5 volt or less, go to step 11).
9. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of MAP sensor signal circuit between MAP sensor connector and PCM connector terminal No. 36. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, repair open MAP sensor signal circuit between MAP sensor connector and PCM connector. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A.
10. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of MAP sensor 5-volt supply circuit. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on MAP sensor 5-volt supply circuit. Perform TEST VER-2A.
11. Using an ohmmeter, check resistance of MAP sensor 5-volt supply circuit between MAP sensor connector and PCM connector terminal No. 61. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, repair open MAP sensor 5-volt supply circuit between MAP sensor connector and PCM connector. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A.

MAP SENSOR CONNECTOR WIRE IDENTIFICATION

TEST TC-61A - INJECTOR NO. 4 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect injector No. 4 connector. Using an ohmmeter, check resistance across injector No. 4 terminals. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, replace injector No. 4. Perform TEST VER-2A.
2. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector No. 4 connector ASD relay output circuit Black/Red wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open ASD relay output circuit. Perform TEST VER-2A.
3. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of PCM connector terminal No. 16 injector No. 4 driver circuit. See INJECTOR NO. 4 CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 4 driver circuit. Perform TEST VER-2A.
4. Using an ohmmeter, check resistance of injector No. 4 driver circuit between injector No. 4 connector and PCM connector terminal No. 16. See INJECTOR NO. 4 CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector No. 4 driver circuit. Perform TEST VER-2A.

INJECTOR NO. 4 CONNECTOR WIRE IDENTIFICATION

TEST TC-61C - INJECTOR NO. 4 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 4 connector. Using an ohmmeter, check resistance of Dark Green/Orange wire between injector No. 4 connector and junction block No. 2 connector (injector side). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Dark Green/Orange wire. Perform TEST VER-2A.
2. Using an ohmmeter, check resistance of Light Blue/Brown wire between injector No. 4 connector and junction block No. 1 connector (injector side). If resistance is less than 5 ohms, replace injector No. 4. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open Light Blue/Brown wire. Perform TEST VER-2A.

TEST TC-62A - O2 SENSOR 1/1 SHORTED TO VOLTAGE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/1 IDENTIFICATION table. Using scan tool, read O2S 1/1 voltage. If voltage is more than 1.2 volts, go to next step. If voltage is 1.2 volts or less, go to step 4). O2 SENSOR 1/1 IDENTIFICATION Application Location 2.5L Rear Bank Upstream O2S
2. Turn ignition off. Disconnect O2S 1/1 connector. Inspect wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If wiring and connectors were repaired, perform TEST VER-5A.
3. Turn ignition on. Using scan tool, read O2S 1/1 voltage. If voltage is more than 1.2 volts, repair short to voltage on O2S 1/1 signal circuit. See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. Perform TEST VER-5A. If voltage is 1.2 volts or less, replace O2S 1/1. Perform TEST VER-5A. O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) Application Wire Color O2S 1/1 Sensor Signal Circuit White/Black O2S 1/1 Sensor Ground Circuit Black/Dark Green
4. While monitoring scan tool display, wiggle O2S wiring harness. If O2S 1/1 voltage goes to more than 1.2 volts at any time while wiggling wiring harness, repair intermittent short to voltage in wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-5A. If O2S 1/1 voltage was not more than 1.2 volts at any time while wiggling wiring harness, go to next step.
5. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-5A.
6. Turn ignition off. Disconnect O2S 1/1 connector. Inspect wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-5A. If wiring and connectors were repaired, perform TEST VER-5A.

TEST TC-65A - O2S 2/1 STAYS AT CENTER

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/1 IDENTIFICATION table. Start engine. Allow engine to reach normal operating temperature. Using scan tool, set engine speed to 1500 RPM. Using scan tool, read O2S 2/1 state. If O2S 2/1 state is switching, go to next step. If O2S 2/1 state is not switching, go to step 6). O2 SENSOR 2/1 IDENTIFICATION Application Location 2.5L Front Bank Upstream O2S
2. While monitoring scan tool display, wiggle O2S 2/1 wiring harness. If O2S 2/1 state locked at center at any time, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-5A. If O2S 2/1 state did not lock at center at any time, go to next step.
3. Turn ignition off. Disconnect O2S 2/1 connector. Inspect wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If wiring and connectors were repaired, perform TEST VER-5A.
4. Condition to set trouble code is not present at this time. O2S 2/1 STAYS AT CENTER DTC sets if O2S 2/1 signal voltage stays .35-.55 volts for 1.5 minutes. Possible causes are: O2S 2/1 output wire open, O2S 2/1 failure, PCM failure or dirt, moisture or grease causing voltage tracking in connector. Go to next step.
5. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-5A. If related wiring and connectors were repaired, perform TEST VER-5A.
6. Turn ignition off. Disconnect O2S 2/1 connector. Inspect wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If wiring and connectors were repaired, perform TEST VER-5A.
7. Using an ohmmeter, check resistance of O2S 2/1 connector (harness side) sensor ground circuit. See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open O2S 2/1 ground circuit. Perform TEST VER-5A.
8. Turn ignition on. Connect a jumper wire between O2S 2/1 connector (harness side) signal circuit and battery voltage. See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. Using scan tool, read O2S 2/1 voltage. If voltage is one volt or less, go to next step. If voltage is more than one volt, replace O2S 2/1. Perform TEST VER-5A.
9. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Disconnect jumper wire from O2S 2/1 connector. Using an ohmmeter, check resistance of O2S 2/1 sensor signal circuit between O2S 2/1 connector and PCM terminal No. 29. See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-5A. If resistance is 5 ohms or more, repair open O2S 2/1 signal ground circuit. Perform TEST VER-5A.

O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-66A - O2 SENSOR 2/1 SHORTED TO VOLTAGE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/1 IDENTIFICATION table. Start engine and let idle for at least 4 minutes. Using scan tool, read O2S 2/1 voltage. If voltage is more than 1.2 volts, go to step 4). If voltage is 1.2 volts or less, go to next step.
2. While monitoring scan tool display, wiggle O2S wiring harness. If O2S 2/1 voltage goes to more than 1.2 volts at any time while wiggling wiring harness, repair intermittent short to voltage in wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-5A. If O2S 2/1 voltage was not more than 1.2 volts at any time while wiggling wiring harness, go to next step.
3. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-5A.
4. Disconnect O2S 2/1 connector. Inspect wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If wiring and connectors were repaired, perform TEST VER-5A.
5. Turn ignition on. Using scan tool, read O2S 2/1 voltage. If voltage is more than 1.2 volts, repair short to voltage on O2S 2/1 signal circuit. See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. Perform TEST VER-5A. If voltage is 1.2 volts or less, replace O2S 2/1. Perform TEST VER-5A.

O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-69A - INJECTOR NO. 5 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Disconnect injector harness 10-pin connector.
2. Using an ohmmeter, check resistance on injector harness connector (injector side) between Red/White wire and Black/Red wire. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, perform TEST TC-69B.
3. Move ohmmeter lead from Black/Red wire to ground. Observe ohmmeter reading. If ohmmeter reading is 5 ohms or more, go to next step. If ohmmeter reading is less than 5 ohms, repair short to ground on injector No. 5 driver circuit Red/White wire. Perform TEST VER-2A.
4. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector connector (PCM side) ASD relay output circuit Black/Red wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open Black/Red wire. Perform TEST VER-2A.
5. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance on PCM connector terminal No. 15 injector No. 1 driver circuit Red/White wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 5 driver circuit. Perform TEST VER-2A.
6. Using an ohmmeter, check resistance of injector No. 5 driver circuit, Red/White wire between injector connector (PCM side) and PCM connector terminal No. 15. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector driver No. 5 circuit. Perform TEST VER-2A.

TEST TC-69B - INJECTOR NO. 5 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 5 connector. Using an ohmmeter, check resistance of injector No. 5 ASD relay output circuit Black/Red wire between injector No. 5 connector and injector 10-pin connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open injector No. 5 ASD relay output circuit. Perform TEST VER-2A.
2. Using an ohmmeter, check resistance of injector No. 5 driver circuit Red/White wire between injector No. 5 connector and injector 10-pin connector. If resistance is less than 5 ohms, replace injector No. 5. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector No. 5 driver circuit. Perform TEST VER-2A.

TEST TC-69D - INJECTOR NO. 5 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 5 connector. Using an ohmmeter, check resistance of Dark Green/Orange wire between injector No. 5 connector and junction block No. 2 connector (injector side). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Dark Green/Orange wire. Perform TEST VER-2A.
2. Using an ohmmeter, check resistance of Brown/Red wire between injector No. 5 connector and junction block No. 1 connector (injector side). If resistance is less than 5 ohms, replace injector No. 5. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open Brown/Red wire. Perform TEST VER-2A.

TEST TC-69E - INJECTOR NO. 5 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect injector No. 5 connector. Using an ohmmeter, check resistance across injector No. 5 terminals. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, replace injector No. 5. Perform TEST VER-2A.
2. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector No. 5 connector ASD relay output circuit Dark Green/Orange wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open ASD relay output circuit. Perform TEST VER-2A.
3. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of PCM connector terminal No. 15 injector No. 5 driver circuit Brown/Red wire. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 5 driver circuit. Perform TEST VER-2A.
4. Using an ohmmeter, check resistance of injector No. 5 driver circuit Brown/Red wire between PCM connector terminal No. 15 and injector No. 5 connector. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open injector No. 5 driver circuit. Perform TEST VER-2A.

TEST TC-70A - INJECTOR NO. 6 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect injector No. 6 connector. Using an ohmmeter, check resistance across injector No. 6 terminals. If resistance is 10-16 ohms, go to next step. If resistance is not 10-16 ohms, replace injector No. 6. Perform TEST VER-2A.
2. Turn ignition on. Using scan tool, actuate ASD relay. Using a voltmeter, check voltage on injector No. 6 connector ASD relay output circuit Black/Red wire. If voltage cycles high and low, go to next step. If voltage does not cycle high and low, repair open ASD relay output circuit. Perform TEST VER-2A.
3. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of injector No. 6 driver circuit at injector connector. See INJECTOR NO. 6 CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on injector No. 6 driver circuit. Perform TEST VER-2A. INJECTOR NO. 6 CONNECTOR WIRE IDENTIFICATION Application Wire Color Injector No. 6 Driver Circuit Brown/Red
4. Using an ohmmeter, check resistance of injector No. 6 driver circuit between PCM connector terminal No. 14 and injector No. 6 connector. See INJECTOR NO. 6 CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, repair open injector No. 6 driver circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

TEST TC-70C - INJECTOR NO. 6 CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. It may be necessary to remove intake plenum for access to injector connectors. Disconnect injector No. 6 connector. Using an ohmmeter, check resistance of Dark Green/Orange wire between injector No. 6 connector and junction block No. 2 connector (injector side). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Dark Green/Orange wire. Perform TEST VER-2A.
2. Using an ohmmeter, check resistance of Brown/Black wire between injector No. 6 connector and junction block No. 1 connector (injector side). If resistance is less than 5 ohms, replace injector No. 6. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open Brown/Black wire. Perform TEST VER-2A.

TEST TC-83A - KNOCK SENSOR NO. 2 CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Disconnect knock sensor connector. Using an ohmmeter, check resistance on PCM connector terminal No. 25 knock sensor No. 2 signal circuit (Gray/Black wire). If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on Gray/Black wire. Perform TEST VER-2A.
2. Turn ignition on with engine off. Using a voltmeter, check voltage on PCM connector terminal No. 25 knock sensor No. 2 signal circuit (Gray/Black wire). If voltage is 5 volts or less, go to next step. If voltage is more than 5 volts, repair short to voltage on Gray/Black wire. Perform TEST VER-2A.
3. Turn ignition off. Remove intake manifold. Trace and inspect Gray/Black wire. If Gray/Black wire is damaged, repair as necessary. Perform TEST VER-2A. If Gray/Black wire is not damaged, go to next step.
4. Reconnect knock sensor connector. Using an ohmmeter, check resistance of knock sensor No. 2 signal circuit Gray/Black wire between knock sensor connector and PCM connector terminal No. 25. If resistance is less than 5 ohms, replace knock sensor No. 2. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open Gray/Black wire. Perform TEST VER-2A.

TEST TC-88A - MANIFOLD TUNE VALVE SOLENOID CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, actuate Manifold Tune Valve (MTV) solenoid. Using scan tool, read Diagnostic Trouble Codes (DTCs). If scan tool displays MANIFOLD TUNE VALVE SOLENOID CIRCUIT with a run count of zero, go to step 5). If scan tool does not display MANIFOLD TUNE VALVE SOLENOID CIRCUIT with a run count of zero, go to next step.
2. Condition to set trouble code is not present at this time. MANIFOLD TUNE VALVE SOLENOID CIRCUIT DTC sets if MTV solenoid control circuit is not in the expected state when requested to operate by Powertrain Control Module (PCM). Possible causes are: open or shorted control circuit, open fused ignition switch output circuit, open or shorted solenoid control coil or Powertrain Control Module (PCM) failure. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. Using scan tool, read trouble codes. With actuator test still running, wiggle wiring harness between MTV solenoid and PCM. MTV solenoid is located in right rear corner of engine compartment. If MANIFOLD TUNE VALVE SOLENOID CIRCUIT DTC returns, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If MANIFOLD TUNE VALVE SOLENOID CIRCUIT DTC does not return, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. Turn ignition off. Disconnect MTV solenoid connector. Turn ignition on. Using a voltmeter, check voltage on Light Green/Black wire at MTV solenoid connector. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, go to TEST TC-88B.
6. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of Violet/Red wire between MTV solenoid connector and PCM connector terminal No. 39. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open Violet/Red wire. Perform TEST VER-2A.
7. Using an ohmmeter, check resistance of Violet/Red wire on PCM connector terminal No. 39. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on Violet/Red wire. Perform TEST VER-2A.
8. Reconnect MTV solenoid connector. Turn ignition on. Using a voltmeter, check voltage on Violet/Red wire at PCM connector terminal No. 39. If voltage is 10 volts or less, replace MTV solenoid. Perform TEST VER-2A. If voltage is more than 10 volts, replace PCM. Perform TEST VER-2A.

TEST TC-88B - MANIFOLD TUNE VALVE SOLENOID CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Using an ohmmeter, check resistance across MTV solenoid terminals. If resistance is less than 5 ohms, replace MTV solenoid. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open Light Green/Black wire to MTV solenoid connector. Replace fuse No. 20 for fused ignition switch output circuit. Perform TEST VER-2A.

TEST TC-90A - A/C PRESSURE SENSOR VOLTS TOO HIGH

Note. A/C pressure sensor may also be referred to as A/C pressure switch or A/C pressure transducer. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.0L article.

1. Using scan tool, read A/C pressure sensor voltage. If A/C pressure sensor voltage is more than 4.6 volts, go to step 6). If A/C pressure sensor voltage is 4.6 volts or less, go to next step.
2. Wiggle wiring harness and connector from Powertrain Control Module (PCM) to A/C pressure sensor while monitoring A/C pressure sensor voltage. The PCM is located between driver's side front fender and power distribution center, near battery. The A/C pressure sensor is located on A/C refrigerant line on firewall, near front of generator and contains a Gray 4-pin connector.
3. If A/C pressure sensor voltage changes while wiggling wiring harness, repair wiring harness as necessary. Perform TEST VER-2A. If A/C pressure sensor voltage does not change while wiggling wiring harness, go to next step.
4. Conditions required to set DTC are not present at this time. The A/C pressure sensor informs PCM if A/C system pressure is too high or too low. DTC may be stored in PCM when A/C pressure sensor voltage at PCM terminal No. 42 is more than 4.9 volts. Possible causes are: sensor signal open, sensor internally open, defective PCM, open sensor ground, defective connector terminals or wiring. Go to next step.
5. Check for defective wiring or connections at PCM and A/C pressure sensor. If defective wiring or connections exist, repair as necessary. Perform TEST VER-2A. If no defective wiring or connections exist, see INACTIVE TROUBLE CODE CONDITION. Perform TEST VER-2A.
6. Disconnect connector at A/C pressure sensor. The A/C pressure sensor is located on A/C refrigerant line on firewall, near front of generator and contains a Gray 4-pin connector.
7. Using voltmeter, check voltage at terminal No. 4 (Dark Blue wire) on connector for A/C pressure sensor. If voltage is one volt or less, go to next step. If voltage is more than one volt, repair short to voltage on Dark Blue wire. Perform TEST VER-2A.
8. Connect jumper wire between terminals No. 4 (Dark Blue wire) and No. 2 (Black/Light Blue wire) on connector for A/C pressure sensor. Using scan tool, read A/C pressure sensor voltage.
9. If A/C pressure sensor voltage is less than one volt, replace A/C pressure sensor. Perform TEST VER-2A. If A/C pressure sensor voltage is one volt or more, go to next step.
10. Disconnect jumper wire from terminal No. 2 (Black/Light Blue wire) on connector for A/C pressure sensor. Reconnect jumper wire on engine ground with other end still connected to terminal No. 4 (Dark Blue wire) on connector for A/C pressure sensor. Using scan tool, read A/C pressure sensor voltage.
11. If A/C pressure sensor voltage is one volt or more, go to next step. If A/C pressure sensor voltage is less than one volt, repair open circuit in Black/Light Blue wire between PCM and A/C pressure sensor. Perform TEST VER-2A. The PCM is located between driver's side front fender and power distribution center, near battery.
12. Ensure ignition is off. Disconnect connectors from PCM. The PCM is located between driver's side front fender and power distribution center, near battery.
13. Using ohmmeter, check resistance between terminal No. 4 (Dark Blue) wire on connector for A/C pressure sensor and PCM connector terminal No. 42 (Dark Blue wire). If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open circuit in Dark Blue wire between PCM and A/C pressure sensor. Perform TEST VER-2A.

TEST TC-91A - A/C PRESSURE SENSOR VOLTS TOO LOW

Note. A/C pressure sensor may also be referred to as A/C pressure switch or A/C pressure transducer. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 3.0L article.

1. Using scan tool, read A/C pressure sensor voltage. If A/C pressure sensor voltage is less than .2 volt, go to step 6). If A/C pressure sensor voltage is .2 volt or more, go to next step.
2. Wiggle wiring harness and connector from Powertrain Control Module (PCM) to A/C pressure sensor while monitoring A/C pressure sensor voltage. The PCM is located between driver's side front fender and power distribution center, near battery. The A/C pressure sensor is located on A/C refrigerant line on firewall, near front of generator and contains a Gray 4-pin connector.
3. If A/C pressure sensor voltage changes while wiggling wiring harness, repair wiring harness as necessary. Perform TEST VER-2A. If A/C pressure sensor voltage does not change while wiggling wiring harness, go to next step.
4. Conditions required to set DTC are not present at this time. The A/C pressure sensor informs PCM if A/C system pressure is too high or too low. DTC may be stored in PCM when A/C pressure sensor voltage at PCM terminal No. 42 decreases to less than .5 volt or remains less than .098 volt. Possible causes are: sensor signal shorted to ground, sensor internally shorted, defective PCM, defective connector terminals or wiring. Go to next step.
5. Check for defective wiring or connections at PCM and A/C pressure sensor. If defective wiring or connections exist, repair as necessary. Perform TEST VER-2A. If no defective wiring or connections exist, see INACTIVE TROUBLE CODE CONDITION. Perform TEST VER-2A.
6. Disconnect connector at A/C pressure sensor. The A/C pressure sensor is located on A/C refrigerant line on firewall, near front of generator and contains a Gray 4-pin connector.
7. Using voltmeter, check voltage at terminal No. 1 (Violet/White wire) on connector for A/C pressure sensor. If voltage is 4.9 volts or less, repair open circuit in Violet/White wire between PCM and A/C pressure sensor. Perform TEST VER-2A. If voltage is more than 4.9 volts, go to next step.
8. Using scan tool, read A/C pressure sensor voltage with connector disconnected at A/C pressure sensor. If A/C pressure sensor voltage is more than 4.5 volts, replace A/C pressure sensor. Perform TEST VER-2A. If A/C pressure sensor voltage is 4.5 volts or less, go to next step.
9. Ensure ignition is off. Disconnect connectors from PCM. The PCM is located between driver's side front fender and power distribution center, near battery.
10. Using ohmmeter, check resistance between ground and terminal No. 4 (Dark Blue) wire on connector for A/C pressure sensor. If resistance is less than 5 ohms, repair short to ground in Dark Blue wire between PCM and A/C pressure sensor. Perform TEST VER-2A. If resistance is 5 ohms or more, go to next step.
11. Using ohmmeter, check resistance between terminals No. 4 (Dark Blue wire) and No. 2 (Black/Light Blue wire) on connector for A/C pressure sensor. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A. If resistance is less than 5 ohms, repair short between Dark Blue wire and Black/Light Blue wire for A/C pressure sensor. Perform TEST VER-2A.

TEST TC-92A - LOW SPEED FAN CONTROL RELAY CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Scheme 100

1. Using scan tool, actuate low speed fan relay. If low speed fan relay is clicking, go to next step. If low speed fan relay is not clicking, go to step 4).
2. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
3. With actuator test still running, wiggle wiring harness between low speed fan relay and PCM. Low speed fan relay is located in Power Distribution Center (PDC). If wiggling caused an interruption in low speed fan relay clicking, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If wiggling did not cause an interruption in low speed fan relay clicking, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
4. Disconnect low speed fan relay. Low speed fan relay is located in Power Distribution Center (PDC). Using a voltmeter, check voltage on ignition switch output circuit at low speed fan relay connector. (Scheme 100)through 156. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ignition switch output circuit. Perform TEST VER-2A. (Scheme 100): Identifying Low Speed Fan Relay Connector Terminals & Location see scheme 51: Testing Relay
5. Using an ohmmeter, check resistance between low speed fan relay terminals. (Scheme 100) If resistance is less than 100 ohms, go to next step. If resistance is 100 ohms or more, replace low speed fan relay. Perform TEST VER-2A.
6. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of low speed fan relay control circuit at low speed fan relay connector. (Scheme 100)through 156 for terminal identification. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in low speed fan relay control circuit. Perform TEST VER-2A.
7. Using an ohmmeter, measure resistance of low speed fan relay control circuit between low speed fan relay connector and PCM connector terminal No. 55. See PCM CONNECTOR WIRE IDENTIFICATION table and (Scheme 100) for wire identification. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open low speed fan relay control circuit. Perform TEST VER-2A.

PCM CONNECTOR WIRE IDENTIFICATION

TEST TC-93A - HIGH SPEED FAN CONTROL RELAY CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Scheme 101

1. Using scan tool, actuate high speed fan relay. If high speed fan relay is clicking, go to next step. If high speed fan relay is not clicking, go to step 5).
2. Condition to set trouble code is not present at this time. HIGH SPEED FAN CONTROL RELAY CIRCUIT DTC sets if an open or shorted condition is detected in high speed fan relay circuit. Possible causes are: high speed fan relay coil open or shorted, fused ignition switch output circuit open, high speed fan relay control circuit open or shorted or inoperative circuit driver in Powertrain Control Module (PCM). Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. With actuator test still running, wiggle wiring harness between high speed fan relay and PCM. High speed fan relay is located in Power Distribution Center (PDC). If wiggling caused an interruption in high speed fan relay clicking, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If wiggling did not cause an interruption in high speed fan relay clicking, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. Disconnect high speed fan relay. High speed fan relay is located in Power Distribution Center (PDC). Using a voltmeter, check voltage on ignition switch output circuit at high speed fan relay connector. (Scheme 101)through 161. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ignition switch output circuit. Perform TEST VER-2A. (Scheme 101): Identifying High Speed Fan Relay Connector Terminals & Location see scheme 53: Testing Relay
6. Using an ohmmeter, check resistance between high speed fan relay terminals. see scheme 53 If resistance is less than 100 ohms, go to next step. If resistance is 100 ohms or more, replace high speed fan relay. Perform TEST VER-2A.
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of high speed fan relay control circuit at high speed fan relay connector. (Scheme 101) through 161 for terminal identification. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in high speed fan relay control circuit. Perform TEST VER-2A.
8. Using an ohmmeter, measure resistance of high speed fan relay control circuit between high speed fan relay connector and PCM connector terminal No. 69. See PCM CONNECTOR WIRE IDENTIFICATION table and (Scheme 101). for wire identification. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open high speed fan relay control circuit. Perform TEST VER-2A.

PCM CONNECTOR WIRE IDENTIFICATION

TEST TC-101A - FUEL PUMP RELAY CONTROL CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, actuate fuel pump relay. If fuel pump relay is clicking, go to next step. If fuel pump relay is not clicking, go to step 5).
2. Condition to set trouble code is not present at this time. FUEL PUMP RELAY CONTROL CIRCUIT DTC sets if an open or shorted condition is detected in fuel pump relay control circuit. Possible causes are: fuel pump relay coil open or shorted, fused ignition switch output circuit open, fuel pump relay control circuit is open or shorted or inoperative circuit driver in Powertrain Control Module (PCM). Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. For fuel pump relay location (Scheme 102)through 168. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. Start engine. Wiggle wiring harness between fuel pump relay and Powertrain Control Module (PCM). If engine stalls, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If engine did not stall, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. Disconnect fuel pump relay. For fuel pump relay location (Scheme 102) Using a voltmeter, check voltage on fuel pump relay connector fused ignition switch output circuit. (Scheme 102) If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused ignition switch output circuit. Perform TEST VER-2A.
6. Using an ohmmeter, check resistance between fuel pump relay terminals. (Scheme 102) If resistance is less than 100 ohms, go to next step. If resistance is 100 ohms or more, replace fuel pump relay. Perform TEST VER-2A.
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of fuel pump relay control circuit at fuel pump relay connector. (Scheme 102)for terminal identification. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in fuel pump relay control circuit. Perform TEST VER-2A.
8. Using an ohmmeter, measure resistance of fuel pump relay control circuit between fuel pump relay connector and PCM connector terminal No. 74. See PCM CONNECTOR WIRE IDENTIFICATION table and (Scheme 102) for wire identification. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open fuel pump relay control circuit. Perform TEST VER-2A.

PCM CONNECTOR WIRE IDENTIFICATION

Locating Fuel Pump Relay. Scheme 102

Identifying Fuel Pump Relay Connector Terminals. Scheme 103

TEST TC-102A - O2 SENSOR 1/1 SLOW RESPONSE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/1 IDENTIFICATION table. O2 SENSOR 1/1 SLOW RESPONSE DTC sets if upstream O2S 1/1 signal voltage is switching from less than .39 volt to more than .6 volt and back fewer times than required. Possible causes are: exhaust leak, fuel contamination, dirty or wet O2 sensor connector causing voltage tracking or engine mechanical failure. Go to next step. O2 SENSOR 1/1 IDENTIFICATION Application Location 2.5L Rear Bank Upstream O2S
2. Start engine. Check for exhaust system leaks between engine and catalytic converter. If no exhaust system leaks are found, go to next step. If exhaust system leaks are found, repair exhaust system as necessary. Perform TEST VER-5A.
3. Check exhaust for excessive smoke from oil consumption. If high oil consumption is not present, go to next step. If high oil consumption is present, repair engine mechanical failure as necessary. Replace O2S1/1. Perform TEST VER-5A.
4. Turn ignition off. Disconnect O2S 1/1 connector. Using an ohmmeter, check resistance of sensor ground circuit at O2S 1/1 connector (harness side). See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open sensor ground circuit. Perform TEST VER-5A.
5. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector. If condition of PCM connector is okay, replace O2S1/1. Perform TEST VER-5A. If condition of PCM connector is not okay, repair as necessary. Perform TEST VER-5A.

O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-103A - O2S 1/1 HEATER FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/1 IDENTIFICATION table. Using scan tool, read trouble codes. If any other O2 SENSOR 1/1 DTCs are set, perform other tests first. See DTC TEST. If no other O2 SENSOR 1/1 DTCs are set, go to next step. O2 SENSOR 1/1 IDENTIFICATION Application Location 2.5L Rear Bank Upstream O2S
2. Turn ignition on with engine off. Wait 3 minutes. Using scan tool, monitor O2S 1/1 voltage. Wait for voltage reading to stabilize between .4-.6 volt. Using scan tool, actuate O2S 1/1 heater test. Monitor O2S 1/1 voltage for 2 minutes. If O2S 1/1 voltage is still .4-.6 volt, go to step 5). If O2S 1/1 voltage is not .4-.6 volt, go to next step.
3. If referenced to this test from TEST TC-118A, go to TEST TC-118A and continue testing procedure. If not referenced to this test from TEST TC-118A, go to next step.
4. Condition to set trouble code is not present at this time. O2S 1/1 HEATER FAILURE DTC sets if no sensor output signal is received when PCM powers up sensor heater. Possible causes are: open heater element circuit, O2S 1/1 failure, PCM failure, dirt and/or moisture in O2S 1/1 connector, faulty O2S 1/1 heater wires or ASD relay failure. Stop all actuator tests. Test is complete. Perform TEST VER-5A.
5. Disconnect O2S 1/1 connector. Inspect O2S 1/1 connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-2A. If connector is okay, go to next step.
6. With scan tool still actuating O2S 1/1 heater test, using a voltmeter, check voltage of ASD relay output circuit on O2S 1/1 connector (harness side). See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-5A.
7. Using scan tool, stop actuator test. Using an ohmmeter, check resistance of O2S 1/1 heater element. Measure resistance between 2 White wires on O2S 1/1 connector (component side). See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE) table. If resistance is 4-7 ohms, go to next step. If resistance is not 4-7 ohms, replace O2S1/1. Perform TEST VER-5A.
8. Using an ohmmeter, measure resistance of O2S 1/1 heater ground circuit between O2S 1/1 connector (harness side) Black wire and ground. If resistance is less than 5 ohms, replace O2S 1/1. Perform TEST VER-5A. If resistance is 5 ohms or more, repair open Black wire. Perform TEST VER-5A.

O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

O2S 1/1 CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE)

TEST TC-105A - O2S 1/2 HEATER FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/2 IDENTIFICATION table. Using scan tool, read trouble codes. If any other O2 SENSOR 1/2 DTCs are set, perform other tests first. See DTC TEST. If no other O2 SENSOR 1/2 DTCs are set, go to next step. O2 SENSOR 1/2 IDENTIFICATION Application Location 2.5L Rear Bank Downstream O2S
2. Turn ignition on with engine off. Wait 3 minutes. Using scan tool, monitor O2S 1/2 voltage. Wait for voltage reading to stabilize between .4-.6 volt. Using scan tool, actuate O2S 1/2 heater test. Monitor O2S 1/2 voltage for 2 minutes. If O2S 1/2 voltage is still .4-.6 volt, go to step 4). If O2S 1/2 voltage is not .4-.6 volt, go to next step.
3. Condition to set trouble code is not present at this time. O2S 1/2 HEATER FAILURE DTC sets if no sensor output signal is received when PCM powers up sensor heater. Possible causes are: open heater element circuit, O2S 1/2 failure, PCM failure, dirt and/or moisture in O2S 1/2 connector, faulty O2S 1/2 heater wires or ASD relay failure. Stop all actuator tests. Test is complete. Perform TEST VER-5A.
4. Disconnect O2S 1/2 connector. Inspect O2S 1/2 connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-2A. If connector is okay, go to next step.
5. With scan tool still actuating O2S 1/2 heater test, using a voltmeter, check voltage of ASD relay output circuit on O2S 1/2 connector (harness side). See O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-5A.
6. Using scan tool, stop actuator test. Using an ohmmeter, check resistance of O2S 1/2 heater element. Measure resistance between 2 White wires on O2S 1/2 connector (component side). See O2S 1/2 CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE) table. If resistance is 4-7 ohms, go to next step. If resistance is not 4-7 ohms, replace O2S1/2. Perform TEST VER-5A.
7. Using an ohmmeter, measure resistance of O2S 1/2 heater ground circuit between O2S 1/2 connector (harness side) Black wire and ground. If resistance is less than 5 ohms, replace O2S 1/2. Perform TEST VER-5A. If resistance is 5 ohms or more, repair open Black wire. Perform TEST VER-5A.

O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

O2S 1/2 CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE)

TEST TC-106A - MULTIPLE CYLINDER MISFIRE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Repair any other Diagnostic Trouble Codes (DTCs) before proceeding with this test. This DTC will only set if condition occurs during driving. Using scan tool, erase trouble codes.
2. Start engine. Drive vehicle until normal operating temperature is reached. Drive vehicle at a steady rate at various MAP and RPM ranges. DO NOT perform any sharp maneuvers with vehicle, these actions will disable misfire detection. During road test, pull vehicle to side and turn ignition off, then restart engine and continue driving vehicle. Go to next step.
3. Using scan tool, read trouble codes. If MULTIPLE CYLINDER MISFIRE DTC returned, go to step 8). If MULTIPLE CYLINDER MISFIRE DTC did not return, go to next step.
4. If CYLINDER NO. 1-6 MISFIRE DTC returned, go to TEST TC-107A. If CYLINDER NO. 1-6 MISFIRE DTC did not return, connect an engine analyzer to vehicle. Start engine. Using equipment manufacturer's instructions, analyze secondary ignition pattern. If secondary ignition pattern is okay, go to next step. If secondary ignition pattern is not okay, repair secondary ignition system as necessary. Perform TEST VER-2A.
5. Using a spray bottle with water, spray secondary ignition cables. DO NOT spray inductive pick-up of test equipment. If ignition pattern did not change, go to next step. If ignition pattern changed, repair secondary ignition system as necessary. Perform TEST VER-2A.
6. Condition to set trouble code is not present at this time. MULTIPLE CYLINDER MISFIRE DTC sets when a more than 1-3 percent misfire rate is measured during 2 trips or with a 10-30 percent misfire rate during one trip. Possible causes are: ignition coil circuit failure, failed spark plug or wire, malfunctioning fuel pump or restricted fuel filter, mechanical engine failure, EGR malfunction, injector malfunction, restricted exhaust, contaminated fuel, intake restriction, poor Powertrain Control Module (PCM) power grounds, malfunctioning EVAP system or failed PCM. Go to next step.
7. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
8. Turn ignition off. Check for proper spark plug wire installation and routing. If spark plug wire installation and routing are okay, go to next step. If spark plug wire installation and routing are not okay, repair as necessary. Perform TEST VER-2A.
9. Connect an engine analyzer to vehicle. Start engine and let it idle for 2 minutes. Using equipment manufacturer's instructions, analyze secondary ignition pattern. If secondary ignition pattern is okay, go to next step. If secondary ignition pattern is not okay, repair secondary ignition system as necessary. Perform TEST VER-2A.
10. While observing secondary ignition pattern, momentarily remove and reinstall spark plug wires from ignition coil or distributor one at a time. If open secondary ignition voltage is at least 25 k/volts, go to next step. If open secondary ignition voltage is not at least 25 k/volts, replace ignition coil. Perform TEST VER-2A.
11. Turn engine off. Remove all spark plugs and ASD relay. Perform a compression test in all cylinders. If all cylinders have at least 100 psi and are within 25 percent of each other, go to next step. If all cylinders do not have at least 100 psi and/or are not within 25 percent of each other, repair mechanical engine failure as necessary. Perform TEST VER-2A. NOTE: Ensure engine temperature does not exceed 180°F (82°C) for next step.
12. Reinstall spark plugs, spark plug wires and ASD relay. Start engine. Using scan tool, monitor spark advance. Raise engine speed to 2000 RPM. If spark advance changed with RPM, go to next step. If spark advance did not change with RPM, replace PCM. Perform TEST VER-2A.
13. Turn engine off. Connect a vacuum gauge to engine intake. Start engine and run until normal operating temperature is reached. Apply parking brake. Put transmission in Neutral. Observe vacuum gauge. If vacuum gauge reads at least 13 in. Hg, to next step. If vacuum gauge does not read at least 13 in. Hg, go to TEST NTC-18A.
14. While monitoring vacuum gauge, snap throttle open and closed. If vacuum dropped rapidly to zero, go to next step. If vacuum did not drop rapidly to zero, repair restricted exhaust system. Perform TEST VER-2A.
15. Turn ignition off. Release fuel pressure. See FUEL PRESSURE RELEASE. Connect a fuel pressure gauge to fuel rail service port. Turn ignition on. Using scan tool, activate fuel system test. Allow time for fuel pressure gauge to stabilize. Using scan tool, stop fuel system test. Monitor fuel pressure gauge for one minute. If fuel pressure is 10 psi or more, go to next step. If fuel pressure is less than 10 psi, go to TEST NTC-3A.
16. Inspect air cleaner filter and inlet ducts for restrictions. If no restrictions were present, go to next step. If restrictions are present, clean restriction as necessary. Perform TEST VER-2A.
17. Verify all wiring and connectors are okay. Perform following tests in order until problem is found: Secondary ignition patterns. Perform TEST NTC-2A. Fuel pressure. Perform TEST NTC-3A. PCM grounds and power circuits. Perform TEST NTC-11A. EGR system. Perform TEST NTC-13A. Engine mechanical. Perform TEST NTC-18A.

TEST TC-107A - CYLINDER NO. 1-6 MISFIRE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Repair any other Diagnostic Trouble Codes (DTCs) before proceeding with this test. MULTIPLE CYLINDER MISFIRE DTC sets when a more than 2 percent misfire rate is measured during 2 trips or with a 10-30 percent misfire rate during one trip. Possible causes are: ignition coil circuit failure, failed spark plug or wire, mechanical engine failure, injector malfunction or failed Powertrain Control Module (PCM). Go to next step.
2. Turn ignition off. Check for proper spark plug wire installation and routing. If spark plug wire installation and routing are okay, go to next step. If spark plug wire installation and routing are not okay, repair as necessary. Perform TEST VER-2A.
3. Connect an engine analyzer to vehicle. Start engine and let it idle for 2 minutes. Using equipment manufacturer's instructions, analyze secondary ignition pattern. If secondary ignition pattern is okay, go to next step. If secondary ignition pattern is not okay, repair secondary ignition system as necessary. Perform TEST VER-2A.
4. While observing secondary ignition pattern, momentarily remove and reinstall spark plug wires from ignition coil or distributor one at a time. If open secondary ignition voltage is at least 25 k/volts, go to next step. If open secondary ignition voltage is not at least 25 k/volts, replace ignition coil. Perform TEST VER-2A.
5. Using a spray bottle with water, spray secondary ignition cables. DO NOT spray inductive pick-up of test equipment. If ignition pattern did not change, go to next step. If ignition pattern changed, repair secondary ignition system as necessary. Perform TEST VER-2A.
6. Turn engine off. Remove all spark plugs and ASD relay. Perform a compression test in all cylinders. If all cylinders have at least 100 psi and are within 25 percent of each other, go to next step. If all cylinders do not have at least 100 psi and/or are not within 25 percent of each other, repair mechanical engine failure as necessary. Perform TEST VER-2A.
7. Reinstall spark plugs, spark plug wires and ASD relay. Start engine and let it run until normal operating temperature is reached. Using scan tool, perform automatic injector kill test. Observe secondary ignition pattern and engine RPM as each injector is killed. If automatic injector kill test did not show a weak cylinder, go to next step. If automatic injector kill test showed a weak cylinder, inspect engine for a possible mechanical failure. Repair as necessary. If engine is mechanically okay, replace faulty fuel injector. Perform TEST VER-2A.
8. Using scan tool, monitor spark advance. Raise engine speed to 2000 RPM. If spark advance changed with RPM, go to next step. If spark advance did not change with RPM, replace PCM. Perform TEST VER-2A.
9. Turn engine off. Connect a vacuum gauge to engine intake. Start engine and run until normal operating temperature is reached. Apply parking brake. Put transmission in Neutral. Observe vacuum gauge. If vacuum gauge reads at least 13 in. Hg, to next step. If vacuum gauge does not read at least 13 in. Hg, go to TEST NTC-18A.
10. Inspect valve train and valve timing of cylinder with trouble code. If valve timing is okay, check for any Technical Service Bulletins (TSBs) which may apply. If any TSBs are found to apply, perform TSB action as necessary. If no TSBs apply, replace PCM. If valve timing is not okay, repair or replace engine components as necessary. Perform TEST VER-2A.

TEST TC-112A - CATALYST 1/1 EFFICIENCY FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Repair any O2S related Diagnostic Trouble Codes (DTCs) before proceeding with this test. If no O2S related DTCs are set, check for any Technical Service Bulletins (TSBs) which may apply. If any TSBs are found to apply, perform TSB action as necessary. If no TSB's apply, go to next step.
2. CATALYST 1/1 EFFICIENCY FAILURE DTC sets as converter loses its ability to store oxygen. Efficiency drops and oxygen concentration becomes the same downstream as upstream. Output voltage of downstream O2S copies upstream O2S with a time lag seen by the Powertrain Control Module (PCM) between switching of O2S's. Malfunction Indicator Light (MIL) illuminates after 2 trips and remains on. MIL will go out if conditions that set trouble code are not found on 3 subsequent trips. Go to next step.
3. Start engine. Check exhaust system for leaks between engine and downstream O2S. If no exhaust leaks are found, go to next step. If exhaust leaks are found, repair or replace exhaust system parts as necessary. Perform TEST VER-5A.
4. Check exhaust gas for excessive smoke caused by oil consumption. If a high oil consumption condition is not present, go to next step. If a high oil consumption condition is present, repair engine for mechanical failure and replace catalytic converter. Perform TEST VER-5A.
5. A newly installed downstream O2S used with an existing (aging) upstream O2S may cause this trouble code to set. If downstream O2S has been replaced within the last 5000 miles, go to next step. If downstream O2S has not been replaced within the last 5000 miles, replace catalytic converter. Perform TEST VER-5A.
6. If upstream O2S has been replaced within the last 5000 miles, replace catalytic converter. Perform TEST VER-5A. If upstream O2S has not been replaced within the last 5000 miles, replace upstream O2S. Perform TEST VER-5A.

TEST TC-113A - EVAP PURGE FLOW MONITOR FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Replacing Powertrain Control Module (PCM) will not correct this trouble code. Using scan tool, erase Diagnostic Trouble Codes (DTCs). Start engine. Allow engine to reach normal operating temperature. Turn engine off. Turn ignition on. Disconnect purge vacuum hose at evappurge solenoid that goes to canister. Start engine. There should be no flow though evap purge solenoid for 1-2 minutes. If evap purge solenoid does not allow vacuum through within one minute, go to next step. If evap purge solenoid allows vacuum through within one minute, replace evap purge solenoid. Perform TEST VER-2A.
2. After 90 seconds, evap purge solenoid will allow vacuum to cycle intermittently at a steady rate. If evap purge solenoid is allowing vacuum to cycle through intermittently at a steady rate, go to next step. If evap purge solenoid is not allowing vacuum to cycle through intermittently at a steady rate, go to step 5).
3. During this step, DO NOT use more than 5 psi. Turn ignition off. Attempt to blow air through vacuum line that goes to canister. If canister and vacuum line allow air to pass, evap purge solenoid and hoses are okay, go to next step. If canister and vacuum line do not allow air to pass, go to TEST TC-113B.
4. No trouble was found during this test. The following components can be inspected as possible causes for trouble code: damaged rubber hoses from evap purge solenoid to throttle body, plastic connector to evap purge solenoid cracked, evap purge solenoid malfunction, hose plugged from evap purge solenoid to canister, hose plugged from throttle body to solenoid, evap connector terminals and evap connector wires. Test is complete.
5. Disconnect vacuum hose from evap purge solenoid to throttle body at evap purge solenoid. Connect a vacuum gauge to disconnected vacuum hose that goes to throttle body. If vacuum gauge indicates manifold vacuum, go to next step. If vacuum gauge does not indicate manifold vacuum, repair vacuum hose or throttle body. Perform TEST VER-2A.
6. Reconnect vacuum hose from throttle body to evap purge solenoid. Connect a vacuum gauge to canister side of evap purge solenoid. If vacuum gauge indicates 3-7 in. Hg, go to next step. If vacuum gauge does not indicate 3-7 in. Hg, replace evap purge solenoid. Perform TEST VER-2A.
7. Connect a vacuum pump to hose going to evap canister. Apply more than 2 in. Hg vacuum to canister. If canister holds more than 2 in. Hg vacuum, go to next step. If canister does not hold more than 2 in. Hg vacuum, replace evap purge solenoid. Perform TEST VER-2A.
8. Check for plugged hose or plugged vent port on canister. If hose is plugged, repair as necessary. Perform TEST VER-2A. If hose is not plugged, go to next step.
9. If vent port is plugged, clean plugged vent port and retest. Perform TEST VER-2A. If vent port is not plugged, replace evap canister. Perform TEST VER-2A.

TEST TC-113B - EVAP PURGE FLOW MONITOR FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Disconnect purge vacuum hose at canister. Attempt to blow air through vacuum line that goes to canister. If vacuum line allows air to pass, go to next step. If vacuum line does not allow air to pass, repair or replace vacuum line as necessary. Perform TEST VER-2A.
2. Check for plugged vent port on canister. If vent port is plugged, repair plugged vent port and retest. Perform TEST VER-2A. If vent port is not plugged, replace evap canister. Perform TEST VER-2A.

TEST TC-114A - PARK/NEUTRAL SWITCH FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Note. FJ22 bodies are equipped with a transmission range sensor.

1. Using scan tool, read park/neutral switch input state. Observe scan tool display while moving gear selector in and out of Park and Reverse. If scan tool displayed P/N and D/R, go to next step. If scan tool did not display P/N and D/R, go to step 4).
2. Condition to set trouble code is not present at this time. PARK/NEUTRAL SWITCH FAILURE DTC sets if Powertrain Control Module (PCM) detects an incorrect Park/Neutral state for a given mode of vehicle operation. Possible causes are: faulty wiring harness connections, park/neutral switch failure, mechanical transmission failure or PCM failure. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A. Test is complete.
4. Turn ignition off. Put gear selector in Park. If vehicle is equipped with a 4-speed automatic transmission, go to step 7). If vehicle is not equipped with a 4-speed automatic transmission, go to next step.
5. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, connect ohmmeter lead to Park/Neutral switch sense circuit at PCM connector terminal No. 76. See PCM CONNECTOR WIRE IDENTIFICATION table. While observing resistance reading, move gear selector in and out of Park and Reverse. If resistance switched from less than 5 ohms to more than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance did not switch from less than 5 ohms to more than 5 ohms, go to next step.
6. If resistance stayed less than 5 ohms all the time, repair short to ground on Park/Neutral switch sense circuit. Perform TEST VER-2A. If resistance did not stay less than 5 ohms all the time, go to next step.
7. Disconnect park/neutral switch connector. Using an ohmmeter, check resistance of park/neutral switch sense circuit between 3-pin park/neutral switch connector and PCM connector terminal No. 76. See PCM CONNECTOR WIRE IDENTIFICATION table for wire color identification on PCM connector and 3-pin park/neutral switch connector. If resistance is less than 5 ohms, replace park/neutral switch. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open park/neutral switch sense circuit. Perform TEST VER-2A.
8. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, connect ohmmeter lead to Park/Neutral switch sense circuit at PCM connector terminal No. 76. See PCM CONNECTOR WIRE IDENTIFICATION table. While observing resistance reading, move gear selector in and out of Park and Reverse. If resistance switched from less than 5 ohms to more than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance did not switch from less than 5 ohms to more than 5 ohms, go to next step.
9. If resistance stayed less than 5 ohms all the time, repair short to ground on Park/Neutral switch sense circuit. Perform TEST VER-2A. If resistance did not stay less than 5 ohms all the time, go to next step.
10. Disconnect Transmission Range Sensor (TRS) connector. Using an ohmmeter, check resistance of park/neutral switch sense circuit between 10-pin TRS connector and PCM connector terminal No. 76. See PCM CONNECTOR WIRE IDENTIFICATION table for wire color identification on PCM connector and 10-pin TRS connector. If resistance is less than 5 ohms, replace TRS. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open park/neutral switch sense circuit. Perform TEST VER-2A.

PCM CONNECTOR WIRE IDENTIFICATION

TEST TC-115A - POWER STEERING SWITCH FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Disconnect power steering pressure switch connector. Connect a jumper wire to power steering pressure switch sense circuit. See POWER STEERING PRESSURE SWITCH CONNECTOR WIRE IDENTIFICATION table. Using scan tool, monitor power steering pressure switch. While observing scan tool, touch jumper wire to ground 5 times. If power steering pressure switch changed from hi to low, go to next step. If power steering pressure switch did not change from hi to low, go to step 3).
2. Replace power steering pressure switch. Perform TEST VER-2A.
3. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of power steering pressure switch sense circuit between power steering pressure switch connector and PCM connector terminal No. 45. See POWER STEERING PRESSURE SWITCH CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open power steering pressure switch sense circuit. Perform TEST VER-2A.
4. Using an ohmmeter, check resistance of power steering pressure switch sense circuit at power steering pressure switch connector. See POWER STEERING PRESSURE SWITCH CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, repair short to ground on power steering pressure switch sense circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

POWER STEERING PRESSURE SWITCH CONNECTOR WIRE IDENTIFICATION

TEST TC-115B - POWER STEERING SWITCH FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Using an ohmmeter, check resistance of power steering pressure switch connector ground circuit. See POWER STEERING PRESSURE SWITCH CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, replace power steering pressure switch. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open ground circuit. Perform TEST VER-2A.

TEST TC-118A - 1/1 FUEL SYSTEM RICH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Repair any O2S related Diagnostic Trouble Codes (DTCs) before proceeding with this test. If no O2S related DTCs are set, check for any Technical Service Bulletins (TSBs) which may apply. If any TSBs are found to apply, perform TSB action as necessary. If no TSBs apply, go to next step.
2. 1/1 FUEL SYSTEM RICH DTC sets when the Powertrain Control Module (PCM) performs a test to determine if fuel system is running too rich. If fuel system is running too rich for 2 trips, Malfunction Indicator Light (MIL) illuminates and a trouble code is stored. MIL remains on for more than one trip but goes out if conditions which occurred to set code are not found on subsequent trips. Possible causes are: plugged catalyst, failed PCM, engine parts tolerance, injectors stuck open, malfunctioning MAP sensor, malfunctioning upstream O2S or faulty fuel pressure regulator. Go to next step.
3. Perform O2S heater test to verify O2S heater is okay. See TEST TC-103A. If TEST TC-103A passed, go to next step. If TEST TC-103A did not pass, repair as necessary under TEST TC-103A. Test is complete. Perform TEST VER-5A.
4. Turn engine off. Inspect cam and/or valve timing. If cam and/or valve timing are okay, go to next step. If cam and/or valve timing are not okay, repair as necessary. Perform TEST VER-5A.
5. Turn engine off. Turn ignition on. Using scan tool, read long term adaptive memory value. If long term adaptive memory is between negative 20 percent and negative 38 percent, go to TEST TC-118B. If long term adaptive memory is not between negative 20 percent and negative 38 percent, condition to set trouble code is no longer present. Test is complete. Perform TEST VER-5A.

TEST TC-118B - 1/1 FUEL SYSTEM RICH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Inspect all O2S wiring and connectors. Repair wiring and connectors as necessary. Perform TEST VER-5A. If wiring and connectors are okay, perform following tests in order until problem is found

1. Fuel pressure. Perform TEST NTC-3A.
2. Coolant temperature sensor. Perform TEST NTC-4A.
3. Throttle position sensor. Perform TEST NTC-5A.
4. MAP sensor. Perform TEST NTC-6A.
5. Evaporative emission system. Perform TEST NTC-12A.
6. EGR system. Perform TEST NTC-13A.
7. Engine mechanical systems. Perform TEST NTC-18A.

TEST TC-119A - 1/1 FUEL SYSTEM LEAN

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. A very low fuel level could cause this trouble code to set. Ensure fuel tank is at least 1/4 full. If vehicle ran out of fuel shortly before coming in for service, erase trouble codes. Test is complete. Perform TEST VER-5A. If vehicle did not run out of fuel shortly before coming in for service, go to next step.
2. 1/1 FUEL SYSTEM LEAN DTC sets when the Powertrain Control Module (PCM) performs a test to determine if fuel system is running too lean. If fuel system is running too lean for 2 trips, Malfunction Indicator Light (MIL) illuminates and a trouble code is stored. MIL remains on for more than one trip but goes out if conditions which occurred to set code are not found on subsequent trips. Possible causes are: faulty ignition coil, failed PCM, engine parts tolerance, leaking exhaust pipe/manifold, faulty fuel pump, plugged fuel filter, faulty secondary ignition cables, low fuel level, injectors stuck closed, faulty Manifold Absolute Pressure (MAP) sensor, faulty upstream O2S, faulty fuel pressure regulator, faulty fuel pump relay or faulty spark plugs. Go to next step.
3. Using scan tool, read trouble codes. If any other related trouble codes are set that can cause a lean condition, perform appropriate trouble code test. If no other related trouble codes are set that can cause a lean condition, go to next step.
4. Turn engine off. Inspect cam and/or valve timing. If cam and/or valve timing are okay, go to next step. If cam and/or valve timing are not okay, repair as necessary. Perform TEST VER-5A.
5. Start engine. Allow engine to idle. Run engine until normal operating temperature is reached. Check exhaust system for leaks between engine and upstream O2S. If exhaust leaks are present, repair exhaust leak as necessary. Perform TEST VER-5A. If exhaust leaks are not present, go to next step.
6. Using scan tool, monitor O2S 1/1 state for 20 seconds or more. If O2S 1/1 state is not switching LEAN-CENTER-RICH twice or more in 20 seconds, go to next step. If O2S 1/1 state is switching LEAN-CENTER-RICH twice or more in 20 seconds, condition required to set trouble code is no longer present. Perform TEST VER-5A.
7. Using scan tool, read long term adaptive memory value. If long term adaptive memory is between positive 20 percent and positive 32 percent, go to TEST TC-119B. If long term adaptive memory is not between positive 20 percent and positive 32 percent, condition to set trouble code is no longer present. Test is complete. Perform TEST VER-5A.

TEST TC-119B - 1/1 FUEL SYSTEM LEAN

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Inspect all O2S wiring and connectors. Repair wiring and connectors as necessary. Perform TEST VER-5A. If wiring and connectors are okay, perform following tests in order until problem is found

1. Fuel pressure. Perform TEST NTC-3A.
2. Ignition system. Perform TEST NTC-2A.
3. Coolant temperature sensor. Perform TEST NTC-4A.
4. MAP sensor. Perform TEST NTC-6A.
5. Engine mechanical systems. Perform TEST NTC-18A.

TEST TC-120A - 2/1 BANK FUEL SYSTEM RICH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Repair any O2S related Diagnostic Trouble Codes (DTCs) before proceeding with this test. If no O2S related DTCs are set, check for any Technical Service Bulletins (TSBs) which may apply. If any TSBs are found to apply, perform TSB action as necessary. If no TSBs apply, go to next step.
2. 2/1 FUEL SYSTEM RICH DTC sets when the Powertrain Control Module (PCM) performs a test to determine if fuel system is running too rich. If fuel system is running too rich for 2 trips, Malfunction Indicator Light (MIL) illuminates and a trouble code is stored. MIL remains on for more than one trip but goes out if conditions which occurred to set code are not found on subsequent trips. Possible causes are: plugged catalyst, failed PCM, engine parts tolerance, injectors stuck open, malfunctioning MAP sensor, malfunctioning upstream O2S or faulty fuel pressure regulator. Go to next step.
3. Perform O2S heater test to verify O2S heater is okay. See TEST TC-142A. If TEST TC-142A passed, go to next step. If TEST TC-142A did not pass, repair as necessary under TEST TC-142A. Test is complete. Perform TEST VER-5A.
4. Turn engine off. Inspect cam and/or valve timing. If cam and/or valve timing are okay, go to next step. If cam and/or valve timing are not okay, repair as necessary. Perform TEST VER-5A.
5. Turn engine off. Turn ignition on. Using scan tool, read long term adaptive memory value. If long term adaptive memory is between negative 20 percent and negative 38 percent, go to TEST TC-120B. If long term adaptive memory is not between negative 20 percent and negative 38 percent, condition to set trouble code is no longer present. Test is complete. Perform TEST VER-5A.

TEST TC-120B - 2/1 FUEL SYSTEM RICH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Inspect all O2S wiring and connectors. Repair wiring and connectors as necessary. Perform TEST VER-5A. If wiring and connectors are okay, perform following tests in order until problem is found

1. Fuel pressure. Perform TEST NTC-3A.
2. Coolant temperature sensor. Perform TEST NTC-4A.
3. Throttle position sensor. Perform TEST NTC-5A.
4. MAP sensor. Perform TEST NTC-6A.
5. Evaporative emission system. Perform TEST NTC-12A.
6. EGR system. Perform TEST NTC-13A.
7. Engine mechanical systems. Perform TEST NTC-18A.

TEST TC-121A - 2/1 FUEL SYSTEM LEAN

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. A very low fuel level could cause this trouble code to set. Ensure fuel tank is at least 1/4 full. If vehicle ran out of fuel shortly before coming in for service, erase trouble codes. Test is complete. Perform TEST VER-5A. If vehicle did not run out of fuel shortly before coming in for service, go to next step.
2. 2/1 FUEL SYSTEM LEAN DTC sets when the Powertrain Control Module (PCM) performs a test to determine if fuel system is running too lean. If fuel system is running too lean for 2 trips, Malfunction Indicator Light (MIL) illuminates and a trouble code is stored. MIL remains on for more than one trip but goes out if conditions which occurred to set code are not found on subsequent trips. Possible causes are: faulty ignition coil, failed PCM, engine parts tolerance, leaking exhaust pipe/manifold, faulty fuel pump, plugged fuel filter, faulty secondary ignition cables, low fuel level, injectors stuck closed, faulty Manifold Absolute Pressure (MAP) sensor, faulty upstream O2S, faulty fuel pressure regulator, faulty fuel pump relay or faulty spark plugs. Go to next step.
3. Using scan tool, read trouble codes. If any other related trouble codes are set that can cause a lean condition, perform appropriate trouble code test. If no other related trouble codes are set that can cause a lean condition, go to next step.
4. Turn engine off. Inspect cam and/or valve timing. If cam and/or valve timing are okay, go to next step. If cam and/or valve timing are not okay, repair as necessary. Perform TEST VER-5A.
5. Start engine. Allow engine to idle. Run engine until normal operating temperature is reached. Check exhaust system for leaks between engine and upstream O2S. If exhaust leaks are present, repair exhaust leak as necessary. Perform TEST VER-5A. If exhaust leaks are not present, go to next step.
6. Using scan tool, monitor O2S 2/1 state for 20 seconds or more. If O2S 2/1 state is not switching LEAN-CENTER-RICH twice or more in 20 seconds, go to next step. If O2S 2/1 state is switching LEAN-CENTER-RICH twice or more in 20 seconds, condition required to set trouble code is no longer present. Perform TEST VER-5A.
7. Using scan tool, read long term adaptive memory value. If long term adaptive memory is between positive 20 percent and positive 32 percent, go to TEST TC-121B. If long term adaptive memory is not between positive 20 percent and positive 32 percent, condition to set trouble code is no longer present. Test is complete. Perform TEST VER-5A.

TEST TC-121B - 2/1 FUEL SYSTEM LEAN

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Inspect all O2S wiring and connectors. Repair wiring and connectors as necessary. Perform TEST VER-5A. If wiring and connectors are okay, perform following tests in order until problem is found

1. Fuel pressure. Perform TEST NTC-3A.
2. Ignition system. Perform TEST NTC-2A.
3. Coolant temperature sensor. Perform TEST NTC-4A.
4. MAP sensor. Perform TEST NTC-6A.
5. Engine mechanical systems. Perform TEST NTC-18A.

TEST TC-122A - O2 SENSOR 2/1 SLOW RESPONSE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/1 IDENTIFICATION table. O2 SENSOR 2/1 SLOW RESPONSE DTC sets if upstream O2S 2/1 signal voltage is switching from less than .39 volt to more than .6 volt and back fewer times than required. Possible causes are: exhaust leak, fuel contamination, dirty or wet O2 sensor connector causing voltage tracking or engine mechanical failure. Go to next step. O2 SENSOR 2/1 IDENTIFICATION Application Location 2.5L Front Bank Upstream O2S
2. Start engine. Check for exhaust system leaks between engine and catalytic converter. If no exhaust system leaks are found, go to next step. If exhaust system leaks are found, repair exhaust system as necessary. Perform TEST VER-5A.
3. Check exhaust for excessive smoke from oil consumption. If high oil consumption is not present, go to next step. If high oil consumption is present, repair engine mechanical failure as necessary. Replace O2S2/1. Perform TEST VER-5A.
4. Turn ignition off. Disconnect O2S 2/1 connector. Using an ohmmeter, check resistance of sensor ground circuit at O2S 2/1 connector (harness side). See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open sensor ground circuit. Perform TEST VER-5A.
5. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector. If condition of PCM connector is okay, replace O2S2/1. Perform TEST VER-5A. If condition of PCM connector is not okay, repair as necessary. Perform TEST VER-5A.

O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-124A - O2 SENSOR 2/1 HEATER FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/1 IDENTIFICATION table. Turn ignition on with engine off. Using scan tool, monitor O2S 2/1 voltage. Wait for voltage reading to stabilize between .4-.6 volt. Using scan tool, actuate O2S 2/1 heater test. Monitor O2S 2/1 voltage for 2 minutes. If O2S 2/1 voltage is still .4-.6 volt, go to step 3). If O2S2/1 voltage is not .4-.6 volt, go to next step. O2 SENSOR 2/1 IDENTIFICATION Application Location 2.5L Front Bank Upstream O2S
2. Condition to set trouble code is not present at this time. O2S 2/1 HEATER FAILURE DTC sets if sensor voltage is more than 3 volts for 30-90 seconds. Possible causes are: open heater element circuit, O2S 2/1 failure, PCM failure, dirt and/or moisture in O2S 2/1 connector or faulty O2S 2/1 heater wires. Stop all actuator tests. Test is complete. Perform TEST VER-5A.
3. Disconnect O2S 2/1 connector. Inspect O2S 2/1 connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
4. With scan tool still actuating O2S 2/1 heater test, using a voltmeter, check voltage of ASD relay output circuit on O2S 2/1 connector (harness side). See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-5A.
5. Using scan tool, stop actuator test. Using an ohmmeter, check resistance of O2S 2/1 heater element. Measure resistance between 2 White wires on O2S 2/1 connector (component side). See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE) table. If resistance is 4-7 ohms, go to next step. If resistance is not 4-7 ohms, replace O2S2/1. Perform TEST VER-5A.
6. Using an ohmmeter, measure resistance of O2S 2/1 heater ground circuit between O2S 2/1 connector (harness side) Black wire and ground. If resistance is less than 5 ohms, replace O2S 2/1. Perform TEST VER-5A. If resistance is 5 ohms or more, repair open Black wire. Perform TEST VER-5A.

O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

O2S 2/1 CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE)

TEST TC-125A - O2 SENSOR 2/2 HEATER FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/2 IDENTIFICATION table. Turn ignition on with engine off. Using scan tool, monitor O2S 2/2 voltage. Wait for voltage reading to stabilize between .4-.6 volt. Using scan tool, actuate O2S 2/2 heater test. Monitor O2S 2/2 voltage for 2 minutes. If O2S 2/2 voltage is still .4-.6 volt, go to step 3). If O2S2/2 voltage is not .4-.6 volt, go to next step.
2. Condition to set trouble code is not present at this time. O2S 2/1 HEATER FAILURE DTC sets if sensor voltage is more than 3 volts for 30-90 seconds. Possible causes are: open heater element circuit, O2S 2/1 failure, PCM failure, dirt and/or moisture in O2S 2/1 connector or faulty O2S 2/1 heater wires. Stop all actuator tests. Test is complete. Perform TEST VER-5A.
3. Disconnect O2S 2/2 connector. Inspect O2S 2/2 connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
4. With scan tool still actuating O2S 2/2 heater test, using a voltmeter, check voltage of ASD relay output circuit on O2S 2/2 connector (harness side). See O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-5A.
5. Using scan tool, stop actuator test. Using an ohmmeter, check resistance of O2S 2/2 heater element. Measure resistance between 2 White wires on O2S 2/2 connector (component side). See O2S 2/2 CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE) table. If resistance is 4-7 ohms, go to next step. If resistance is not 4-7 ohms, replace O2S2/2. Perform TEST VER-5A.
6. Using an ohmmeter, measure resistance of O2S 2/2 heater ground circuit between O2S 2/2 connector (harness side) Black wire and ground. If resistance is less than 5 ohms, replace O2S 2/2. Perform TEST VER-5A. If resistance is 5 ohms or more, repair open Black wire. Perform TEST VER-5A.

O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

O2S 2/2 CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE)

TEST TC-126A - O2 SENSOR 1/2 SHORTED TO VOLTAGE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/2 IDENTIFICATION table. Using scan tool, read O2S 1/2 voltage. If voltage is more than 1.2 volts, go to next step. If voltage is 1.2 volts or less, go to step 3). O2 SENSOR 1/2 IDENTIFICATION Application Location 2.5L Rear Bank Downstream O2S
2. Disconnect O2S 1/2 connector. Observe O2S 1/2 voltage. If voltage is more than 1.2 volts, repair short to voltage on O2S 1/2 signal circuit. See O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. Perform TEST VER-5A. If voltage is 1.2 volts or less, replace O2S 1/2. Perform TEST VER-5A. O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) Application Wire Color O2S 1/2 Sensor Signal Circuit White/Dark Green O2S 1/2 Sensor Ground Circuit Black/Dark Green
3. While monitoring scan tool display, wiggle O2S wiring harness. If O2S 1/2 voltage goes to more than 1.2 volts at any time while wiggling wiring harness, repair intermittent short to voltage in wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-5A. If O2S 1/2 voltage was not more than 1.2 volts at any time while wiggling wiring harness, go to next step.
4. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-5A.
5. Turn ignition off. Disconnect O2S 2/2 connector. Inspect wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, using a wiring diagram as a guide, inspect wiring harness and repair as necessary. Perform TEST VER-5A. If no problems were found with wiring harness, test is complete. Perform TEST VER-5A.

TEST TC-127A - O2 SENSOR 2/2 SHORTED TO VOLTAGE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/2 IDENTIFICATION table. Using scan tool, read O2S 2/2 voltage. If voltage is more than 1.2 volts, go to next step. If voltage is 1.2 volts or less, go to step 3). O2 SENSOR 2/2 IDENTIFICATION Application Location 2.5L Front Bank Downstream O2S
2. Disconnect O2S 2/2 connector. Observe O2S 2/2 voltage. If voltage is more than 1.2 volts, repair short to voltage on O2S 2/2 signal circuit. See O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. Perform TEST VER-5A. If voltage is 1.2 volts or less, replace O2S 2/2. Perform TEST VER-5A. O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) Application Wire Color O2S 2/2 Sensor Signal Circuit White/Red O2S 2/2 Sensor Ground Circuit Black/Dark Green
3. While monitoring scan tool display, wiggle O2S wiring harness. If O2S 2/2 voltage goes to more than 1.2 volts at any time while wiggling wiring harness, repair intermittent short to voltage in wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-5A. If O2S 2/2 voltage was not more than 1.2 volts at any time while wiggling wiring harness, go to next step.
4. Condition to set trouble code is not present at this time. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-5A.
5. Turn ignition off. Disconnect O2S 2/2 connector. Inspect wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, using a wiring diagram as a guide, inspect wiring harness and repair as necessary. Perform TEST VER-5A. If no problems were found with wiring harness, test is complete. Perform TEST VER-5A.

TEST TC-128A - CLOSED LOOP TEMP NOT REACHED

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. This test procedure is not valid if thermostat is stuck open. If thermostat is operating correctly, go to next step. If thermostat is not operating correctly, replace thermostat. Perform TEST VER-2A.
2. CLOSED LOOP TEMP NOT REACHED DTC sets if engine temperature does not rise to more than 60°F (16°C) within 10 minutes after engine is started. Possible causes are: thermostat failure, Engine Coolant Temperature (ECT) failure, extremely cold ambient temperature conditions or Powertrain Control Module (PCM) failure. Go to next step.
3. Run engine until engine coolant temperature is more than 80°F (27°C). Turn ignition off. Disconnect PCM connector. Inspect PCM connector for damaged or pushed out terminals. Repair PCM connector as necessary. Perform TEST VER-2A. If PCM connector is okay, go to next step.
4. Using an ohmmeter, connect one ohmmeter lead to PCM connector terminal No. 26 ECT sensor signal circuit. Connect other ohmmeter lead to PCM connector terminal No. 43 ECT sensor ground circuit. See PCM CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 11 k/ohms, replace PCM. Perform TEST VER-2A. If resistance is 11k/ohms or more, replace ECT sensor. Perform TEST VER-2A.

PCM CONNECTOR WIRE IDENTIFICATION

TEST TC-129A - O2 SENSOR 1/2 STAYS AT CENTER

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/2 IDENTIFICATION table. Turn ignition on with engine off. Using scan tool, monitor O2S 1/2 voltage. Wait for voltage reading to stabilize between .4-.6 volt. Using scan tool, actuate O2S 1/2 heater test. Monitor O2S 1/2 voltage for 2 minutes. If O2S 1/2 voltage is still .4-.6 volt, go to step 4 . If O2S1/2 voltage is not .4-.6 volt, go to next step. O2 SENSOR 1/2 IDENTIFICATION Application Location 2.5L Rear Bank Downstream O2S
2. Using scan tool, stop actuation test. Turn ignition off. Disconnect O2S 1/2 connector. Inspect O2S 1/2 connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
3. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, replace O2S 1/2. Perform TEST VER-5A.
4. Using scan tool, stop actuation test. Turn ignition off. Disconnect O2S 1/2 connector. Inspect O2S 1/2 connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
5. Using an ohmmeter, check resistance of O2S ground circuit at O2S connector (harness side). See O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open sensor ground circuit. Perform TEST VER-5A. O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) Application Wire Color O2S 1/2 Signal Circuit White/Dark Green O2S 1/2 Sensor Ground Circuit Black/Dark Green
6. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
7. Using an ohmmeter, measure resistance of O2S 1/2 signal circuit between O2S 1/2 connector (harness side) and PCM connector terminal No. 51. See O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open O2S signal circuit. Perform TEST VER-5A.
8. Reconnect PCM connector. Turn ignition on. Connect a jumper wire between O2S signal circuit and sensor ground circuit terminals at O2S 1/2 connector (harness side). See O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. Using scan tool, read O2S 1/2 volts. If voltage less than 0.2 volt, replace O2S 1/2. Perform TEST VER-5A. If voltage is 0.2 volt or more, replace PCM. Perform TEST VER-5A.

TEST TC-130A - O2S 2/2 STAYS AT CENTER

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/2 IDENTIFICATION table. Turn ignition on with engine off. Using scan tool, monitor O2S 2/2 voltage. Wait for voltage reading to stabilize between .4-.6 volt. Using scan tool, actuate O2S 2/2 heater test. Monitor O2S 2/2 voltage for 2 minutes. If O2S 2/2 voltage is still .4-.6 volt, go to step 4). If O2S2/2 voltage is not .4-.6 volt, go to next step. O2 SENSOR 2/2 IDENTIFICATION Application Location 2.5L Front Bank Downstream O2S
2. Using scan tool, stop actuation test. Turn ignition off. Disconnect O2S 2/2 connector. Inspect O2S 2/2 connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
3. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, replace O2S 2/2. Perform TEST VER-5A.
4. Using scan tool, stop actuation test. Turn ignition off. Disconnect O2S 2/2 connector. Inspect O2S 2/2 connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
5. Using an ohmmeter, check resistance of O2S ground circuit at O2S connector (harness side). See O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open sensor ground circuit. Perform TEST VER-5A. O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) Application Wire Color O2S 2/2 Sensor Signal Circuit White/Red O2S 2/2 Sensor Ground Circuit Black/Dark Green
6. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for damaged, pushed out or miswired terminals. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
7. Using an ohmmeter, measure resistance of O2S 2/2 signal circuit between O2S 2/2 connector (harness side) and PCM connector terminal No. 1. See O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open O2S signal circuit. Perform TEST VER-5A.
8. Reconnect PCM connector. Turn ignition on. Connect a jumper wire between O2S signal circuit and sensor ground circuit terminals at O2S 2/2 connector (harness side). See O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. Using scan tool, read O2S 2/2 volts. If voltage less than 0.2 volt, replace O2S 2/2. Perform TEST VER-5A. If voltage is 0.2 volt or more, replace PCM. Perform TEST VER-5A.

TEST TC-132A - TPS VOLTAGE DOES NOT AGREE WITH MAP

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, read Diagnostic Trouble Codes (DTCs). If NO VEHICLE SPEED SENSOR SIGNAL DTC is set, go to TEST TC-35A. If NO VEHICLE SPEED SENSOR SIGNAL DTC is not set, go to next step.
2. If a Manifold Absolute Pressure (MAP) sensor trouble code is set, perform appropriate DTC test. If a MAP sensor trouble code is not set, using scan tool, read MAP sensor voltage. If MAP sensor voltage is 3.5 volts or more, go to next step. If MAP sensor voltage is less than 3.5 volts, go to TEST NTC-6A.
3. Start engine. Using scan tool, read MAP sensor voltage. If MAP sensor voltage dropped from more than 3.5 volts to less than 2 volts, go to next step. If MAP sensor did not drop from more than 3.5 volts to less than 2 volts, go to TEST NTC-6A.
4. TPS VOLTAGE DOES NOT AGREE WITH MAP sets when Powertrain Control Module (PCM) performs one of 2 different tests on Throttle Position (TP) sensor. Tests performed are a high voltage test and a low voltage test. The high voltage test is performed when engine speed is low and manifold vacuum is high. These conditions indicate throttle plate is nearly closed. With throttle plate nearly closed, TP sensor signal voltage output must be low. Go to next step.
5. The low voltage test is performed when vehicle speed is more than 25 MPH and manifold vacuum is low. These conditions indicate throttle plate is open. With vehicle speed more than 25 MPH and throttle plate open, TP sensor signal voltage must be high. If proper TP sensor signal voltage is not present for either high voltage test or low voltage test, this trouble code will set after 4 continuous seconds. Go to next step.
6. Possible causes are: failed PCM, TP sensor failure, engine mechanical failure, connector or wiring harness problem, malfunctioning Vehicle Speed Sensor (VSS) or malfunctioning MAP sensor. Go to next step.
7. Check throttle plate and linkage for binding. Ensure throttle linkage is at idle position. Repair either condition as required. Perform TEST VER-2A. If both conditions are okay, go to next step.
8. If TP sensor ground circuit and 5-volt supply circuit are switched, this trouble code will set. Disconnect TP sensor connector. Inspect TP sensor connector for correct wire placement and damage. If TP sensor connector wire placement is incorrect or damaged, repair as necessary. Perform TEST VER-2A. If TP sensor connector wire placement is correct and not damaged, go to next step.
9. Using a voltmeter, check voltage on TP sensor connector 5-volt supply circuit. See TP SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is 5 volts or more, go to next step. If voltage is less than 5 volts, repair open 5-volt supply circuit. Perform TEST VER-2A.
10. Reconnect TP sensor connector. Turn ignition on with engine off. Using scan tool, read TP sensor voltage. If TP sensor voltage is one volt or less, go to next step. If TP sensor voltage is more than one volt, replace TP sensor. Perform TEST VER-2A.
11. While observing scan tool, slowly open and close throttle. If voltage change is smooth, go to next step. If voltage change is not smooth, replace TP sensor. Perform TEST VER-2A.
12. While observing scan tool, open throttle to Wide Open Throttle (WOT) position. If TP sensor voltage is more than 3.5 volts at WOT, go to next step. If TP sensor voltage is 3.5 volts or less at WOT, replace TP sensor. Perform TEST VER-2A.
13. While monitoring scan tool display, wiggle wiring harness between TP sensor and PCM. If voltage does not change at any time, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If voltage changes at any time, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A.

TP SENSOR CONNECTOR WIRE IDENTIFICATION

TEST TC-133A - TIMING BELT SKIPPED ONE TOOTH OR MORE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. This Diagnostic Trouble Code (DTC) has set because the Powertrain Control Module (PCM) has determined the camshaft and crankshaft are out of synchronization. Go to next step.
2. The TIMING BELT SKIPPED ONE TOOTH OR MORE DTC sets when Camshaft Position (CMP) sensor is offset from Crankshaft Position (CKP) sensor one tooth or more. Possible causes are: engine valve timing out of specification, camshafts relative position not relearned (scan tool function) after one of the following items has been serviced: camshaft, CMP sensor, CMP sensor target magnet, camshaft sprocket, crankshaft, crankshaft sprocket, cylinder block, cylinder head, head gasket, PCM, tensioner, timing belt, water pump has been serviced, or valve timing has been verified or corrected. Go to next step.
3. Inspect engine valve timing. See appropriate article in ENGINES section. If engine valve timing is okay, go to next step. If engine valve timing is off, repair valve timing as necessary. Go to next step. CAUTION: Perform next step ONLY if camshaft, CMP sensor, CMP sensor target magnet, camshaft sprocket, crankshaft, crankshaft sprocket, cylinder block, cylinder head, head gasket, PCM, tensioner, timing belt or water pump has been serviced, or valve timing has been verified or corrected.
4. If engine valve timing is okay or valve timing problem has been corrected, using scan tool, select ADJUSTMENTS. Select RELEARN CMP/CKP. PCM will perform a relearn function automatically. Perform TEST VER-2A.

TEST TC-138A - TARGET IDLE NOT REACHED

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition on with engine off. Check throttle plate and linkage for binding. Ensure throttle linkage is at idle position. Repair either condition as required. Perform TEST VER-2A. If both conditions are okay, go to next step.
2. Start engine. Allow engine to idle for one minute. Using scan tool, read target idle and engine RPM. If engine RPM is within 200 RPM of target idle, go to step 5). If engine RPM is not within 200 RPM of target idle, go to next step. NOTE: For remainder of this test to be valid, engine must not have any vacuum leaks.
3. Verify PCV valve is correct application and operating properly. If PCV valve is correct and operating properly, go to next step. If PCV valve is not correct or operating properly, repair as necessary. Perform TEST VER-2A.
4. Start engine. With engine warm, using scan tool, actuate Idle Air Control (IAC) wiggle test. Idle speed should raise and lower with scan tool display. If IAC motor is operating properly, go to TEST TC-138B. If IAC motor is not operating properly, go to TEST TC-25A.
5. Condition to set trouble code is not present at this time. TARGET IDLE NOT REACHED DTC sets if engine speed is not within 200 RPM greater than or 100 RPM less than target idle for 14 seconds. Possible causes are: Idle Air Control (IAC) driver circuit shorted to ground, IAC driver circuit shorted to battery, IAC driver circuits shorted together, failed Powertrain Control Module (PCM), shorted IAC motor, engine carbon deposits or open IAC driver circuit. Go to next step.
6. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
7. Start engine. With engine warm, using scan tool, actuate Idle Air Control (IAC) wiggle test. Idle speed should raise and lower with scan tool display. If IAC motor is operating properly, go to next step. If IAC motor is not operating properly, go to TEST TC-25A.
8. Observe IAC motor operation. Wiggle wiring harness from IAC motor to PCM. If IAC motor stops operating at any time, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A.
9. Stop IAC wiggle test. See INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.

TEST TC-138B - TARGET IDLE NOT REACHED

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect PCV valve hose from intake manifold. Cap intake manifold vacuum port. Disconnect purge hose from throttle body. Install Orifice (6457) onto throttle body purge hose port. Start engine. Allow engine to reach operating temperature.
2. Using scan tool, actuate minimum airflow. If engine speed is less than 550 RPM, go to next step. If engine speed is 550 RPM or more, replace throttle body. Perform TEST VER-2A.
3. Remove throttle body from engine. Using appropriate cleaner, clean throttle plate and throttle bore. Dry throttle body with compressed air. Install throttle body onto engine. Start engine. Using scan tool, actuate minimum airflow. If engine speed is less than 550 RPM, replace throttle body. Perform TEST VER-2A. If engine speed is 550 RPM or more, test is complete. Perform TEST VER-2A.

TEST TC-139A - HIGH SPEED RADIATOR FAN CONTROL RELAY

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, actuate high speed radiator fan relay. If high speed radiator fan relay is clicking, go to next step. If high speed radiator fan relay is not clicking, go to step 5).
2. Condition to set trouble code is not present at this time. HIGH SPEED RADIATOR FAN CONTROL RELAY CIRCUIT DTC sets if an open or shorted condition is detected in high speed radiator fan relay control circuit. Possible causes are: relay coil open or shorted, fused ignition switch output circuit open, open or shorted relay control circuit or inoperative circuit driver in Powertrain Control Module (PCM). Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. Wiggle wiring harness between high speed radiator fan relay and PCM while scan tool is still actuating high speed radiator fan relay. If wiggling did not cause an interruption of high speed radiator fan relay actuation, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If wiggling caused an interruption of high speed radiator fan relay actuation, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A.
5. Disconnect high speed radiator fan relay. Using a voltmeter, check voltage of high speed radiator fan relay connector ignition switch output circuit. (Scheme 104)or see scheme 58. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ignition switch output circuit. Perform TEST VER-2A.
6. Using a ohmmeter, check resistance between high speed radiator fan relay terminals. see scheme 58 If resistance is less than 100 ohms, go to next step. If resistance is 100 ohms or more, replace high speed radiator fan relay. Perform TEST VER-2A.
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using a ohmmeter, check resistance of high speed radiator fan relay control circuit at relay connector. (Scheme 104)for terminal identification. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in high speed radiator fan relay control circuit. Perform TEST VER-2A.
8. Using a ohmmeter, measure resistance of high speed radiator fan relay control circuit between high speed radiator fan relay connector and PCM connector terminal No. 69. See PCM CONNECTOR WIRE IDENTIFICATION table and (Scheme 104) for wire identification. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open high speed radiator fan relay control circuit. Perform TEST VER-2A.

PCM CONNECTOR WIRE IDENTIFICATION

Identifying High Speed Radiator Fan Control Relay Connector Terminals & Location. Scheme 104

TEST TC-145A - VACUUM LEAK FOUND (IAC FULLY SEATED)

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. The most probable cause of this Diagnostic Trouble Code (DTC) is a massive vacuum leak. VACUUM LEAK FOUND (IAC FULLY SEATED) DTC sets if Manifold Absolute Pressure (MAP) sensor signal does not correlate with Throttle Position (TP) sensor signal. Possible causes are: vacuum leak, faulty MAP sensor, faulty TP sensor or failed Powertrain Control Module (PCM). Go to next step.
2. Inspect intake manifold for vacuum leaks. If a vacuum leak is found, repair as necessary. Perform TEST VER-2A. If a vacuum leak is not found, go to next step.
3. Turn ignition on. Verify throttle is fully closed. Using scan tool, read Throttle Position (TP) sensor voltage. If TP sensor voltage is 1.5 volts or less, go to next step. If TP sensor is more than 1.5 volts, replace TP sensor. Perform TEST VER-2A.
4. While observing scan tool, slowly open and close throttle. If voltage change is smooth, go to next step. If voltage change is not smooth, replace TP sensor. Perform TEST VER-2A.
5. While observing scan tool, open throttle to Wide Open Throttle (WOT) position. If TP sensor voltage is 3.4 volts or more at WOT, go to next step. If TP sensor voltage is less than 3.4 volts at WOT, replace TP sensor. Perform TEST VER-2A.
6. Turn ignition off. Connect a vacuum gauge to an intake manifold vacuum source. Start engine. Allow engine to idle. If engine will not idle, maintain a constant engine RPM. Using scan tool, read MAP sensor vacuum. If scan tool reading is within one in. Hg of vacuum gauge reading, go to next step. If scan tool reading is not within one in. Hg of vacuum gauge reading, replace MAP sensor. Perform TEST VER-2A.
7. If vacuum gauge reads more than 13 in. Hg, replace Powertrain Control Module (PCM). Perform TEST VER-2A. If vacuum gauge reads 13 in. Hg or less, locate and repair engine vacuum leak. Perform TEST VER-2A.

TEST TC-146A - 5 VOLT SUPPLY OUTPUT TOO LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition on with engine off. Disconnect Throttle Position (TP) sensor connector. Using a voltmeter, check voltage on TP sensor connector 5-volt supply circuit. See TP SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is less than 4.5 volts, go to next step. If voltage is 4.5 volts or more, go to TEST TC-146B.
2. With voltmeter still connected to TP sensor connector 5-volt supply circuit, disconnect Manifold Absolute Pressure (MAP) sensor electrical connector. If voltage is 4 volts or less, go to next step. If voltage is more than 4 volts, replace MAP sensor. Perform TEST VER-2A.
3. If vehicle is not equipped with an A/C pressure sensor, go to next step. If vehicle is equipped with an A/C pressure sensor, disconnect A/C pressure sensor connector. If voltage is 4 volts or less, go to next step. If voltage is more than 4 volts, replace A/C pressure sensor. Perform TEST VER-2A.
4. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using a ohmmeter, check resistance of TP sensor 5-volt supply circuit at TP sensor connector. If resistance is less than 5 ohms, repair short to ground on TP sensor 5-volt supply circuit. See TP SENSOR CONNECTOR WIRE IDENTIFICATION table. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

TP SENSOR CONNECTOR WIRE IDENTIFICATION

TEST TC-146B - 5-VOLT SUPPLY OUTPUT TOO LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Reconnect TP sensor connector. Disconnect Manifold Absolute Pressure (MAP) sensor electrical connector. Using a voltmeter, check voltage of 5-volt supply circuit at MAP sensor connector. See MAP SENSOR CONNECTOR WIRE IDENTIFICATION table. If voltage is 4.5 volts or more, go to next step. If voltage is less than 4.5 volts, replace TP sensor. Perform TEST VER-2A.
2. While observing voltmeter connected to MAP sensor connector 5-volt supply circuit, wiggle wiring harness for MAP sensor, A/C pressure sensor and TP sensor. If voltage changed, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change, go to next step.
3. Condition to set trouble code is not present at this time. 5 VOLT SUPPLY OUTPUT TOO LOW DTC sets if 5-volt supply to engine sensors is less than 3.5 volts for 4 seconds. Possible causes are: shorted 5-volt supply circuit or shorted sensor. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.

MAP SENSOR CONNECTOR WIRE IDENTIFICATION

TEST TC-149A - FUEL LEVEL SENDING UNIT VOLTS TOO LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see L-WIRING DIAGRAMS - 2.5L article.

Scheme 105

Scheme 106

1. Go to TEST TC-149B
2. Turn ignition on. Record fuel level gauge reading. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Turn ignition on. Let fuel level gauge stabilize. If fuel level reading is not different with PCM disconnected, go to next step. If fuel level reading is different with PCM disconnected, replace PCM. Perform TEST VER-2A.
3. Using a voltmeter, check voltage on fuel level signal circuit at PCM connector terminal No. 23 (Dark Blue wire). If voltage is.75 volt or more, go to next step. If voltage is less than.75 volt, go to step 7).
4. While observing voltmeter, wiggle wiring harness for fuel level sending unit. If voltage changed, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER- 2A. If voltage did not change, go to next step.
5. Condition to set trouble code is not present at this time. FUEL LEVEL SENDING UNIT VOLTS TOO LOW DTC sets if PCM terminal No. 23 fuel level sensor signal circuit voltage goes less than.10 volt. Possible causes are: fuel level sensor signal circuit shorted to ground, failed fuel level sending unit, loss of ignition switch output voltage, instrument cluster printed circuit board failure or failed PCM. Go to next step.
6. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER- 2A. If related wiring and connectors were repaired, perform TEST VER- 2A.
7. Disconnect 4-pin fuel pump connector. Fuel pump connector is located at fuel tank. Using a voltmeter, check voltage on left instrument cluster connector terminal No. 10 fuel level sensor signal circuit (Dark Blue wire). (Scheme 105) If voltage is less than.75 volt, go to next step. If voltage is.75 volt or more, replace fuel tank sending unit. Perform TEST VER-2A.
8. Turn ignition off. Remove instrument cluster. Using a ohmmeter, check resistance on left instrument cluster connector terminal No. 10 fuel level sensor signal circuit (Dark Blue wire). (Scheme 105) If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on Dark Blue wire. Perform TEST VER-2A. (Scheme 105): Identifying Left Instrument Cluster Connector
9. Turn ignition on. Using a voltmeter, check voltage on right instrument cluster connector terminal No. 5 fused ignition switch output circuit (Dark Blue/White wire). (Scheme 106) If voltage is more than 8 volts, go to next step. If voltage is 8 volts or less, repair open Dark Blue/White wire. Perform TEST VER-2A.
10. Turn ignition off. Connect a jumper wire between 4-pin fuel pump harness connector (at fuel tank) Dark Blue wire and ground. Using a ohmmeter, check resistance of low fuel sense circuit at PCM connector terminal No. 23 (Dark Blue wire). If resistance is less than 5 ohms, replace instrument cluster printed circuit board. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open circuit between PCM connector terminal No. 23 and Dark Blue wire splice. Perform TEST VER-2A. (Scheme 106): Identifying Right Instrument Cluster Connector

TEST TC-149B - FUEL LEVEL SENDING UNIT VOLTS TOO LOW

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

Scheme 107

Scheme 108

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Turn ignition on. Using a voltmeter, check voltage on PCM connector terminal No. 23 low fuel sense circuit (Yellow/Blue wire). If voltage is.5 volt or more, go to next step. If voltage is less than.5 volt, go to step 5).
2. While observing voltmeter, wiggle wiring harness for fuel level sending unit. If voltage changed, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change, go to next step.
3. Condition to set trouble code is not present at this time. FUEL LEVEL SENDING UNIT VOLTS TOO LOW DTC sets if PCM connector terminal No. 23 goes to less than.10 volt. Possible causes are: fuel tank sending unit sensor signal circuit shorted to ground, fuel level sending unit failure, loss of fused ignition switch output voltage, instrument cluster printed circuit board failure or PCM failure. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
5. Disconnect fuel level sending unit connector. Fuel level sending unit connector is located under right side of rear seat. Using a voltmeter, check voltage of low fuel sense circuit at PCM connector terminal No. 23 (Yellow/Blue wire). If voltage is one volt or less, go to next step. If voltage is more than one volt, replace fuel level sending unit. Perform TEST VER-2A.
6. Turn ignition off. Remove instrument cluster. Using a ohmmeter, check resistance of low fuel sense circuit at right instrument cluster connector terminal No. 3 (Yellow/Blue wire). (Scheme 107)and (Scheme 108). If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on Yellow/Blue wire. Perform TEST VER-2A. (Scheme 107): Locating Right Instrument Cluster Connector (Scheme 108): Identifying Right Instrument Cluster Connector Terminals
7. Turn ignition on. Using a voltmeter, check voltage of fused ignition switch output circuit at right instrument cluster connector terminal No. 8 (Black/White wire). If voltage is more than 8 volts, go to next step. If voltage is 8 volts or less, repair open Black/White wire. Perform TEST VER-2A.
8. Inspect low fuel light bulb located in instrument cluster connector. (Scheme 107) If low fuel light bulb is okay, go to next step. If low fuel light bulb is bad, replace low fuel light bulb. Perform TEST VER-2A.
9. Connect a jumper wire at fuel level signal circuit (Yellow wire) between fuel level sending unit connector and ground. Using a ohmmeter, check resistance at PCM connector terminal No. 23 (Yellow/Blue wire). If resistance is less than 5 ohms, replace instrument cluster assembly. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open Yellow/Blue wire between PCM connector and fuel level sending unit connector. Perform TEST VER-2A.

TEST TC-150A - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see L-WIRING DIAGRAMS - 2.5L article.

1. Go to TEST TC-150B.
2. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Turn ignition on. Using a voltmeter, check voltage on fuel level signal circuit at PCM connector terminal No. 23 (Dark Blue wire). If voltage is 9 volts or less, go to next step. If voltage is more than 9 volts, go to step 6).
3. While observing voltmeter, wiggle wiring harness for fuel level sending unit. If voltage changed, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER- 2A. If voltage did not change, go to next step.
4. Condition to set trouble code is not present at this time. FUEL LEVEL SENDING UNIT VOLTS TOO HIGH DTC sets if PCM terminal No. 23 fuel level sensor signal circuit voltage goes more than a calculated value. Possible causes are: open fuel level sensor signal circuit, failed fuel level sending unit, instrument cluster printed circuit board failure or failed PCM. Go to next step.
5. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER- 2A. If related wiring and connectors were repaired, perform TEST VER- 2A.
6. Disconnect fuel pump connector. Fuel pump connector is located at fuel tank. Connect a jumper wire between Dark Blue wire and Black wire at fuel pump connector (harness side). Using a voltmeter, check voltage of PCM connector terminal No. 23 (Dark Blue wire). If voltage is 1.5 volts or more, go to next step. If voltage is less than 1.5 volts, replace fuel level sending unit. Perform TEST VER-2A.
7. Disconnect jumper wire. Reconnect jumper wire to chassis ground. Using a voltmeter, check voltage of PCM connector terminal No. 23 (Dark Blue wire). If voltage is 1.5 volts or more, go to next step. If voltage is less than 1.5 volts, repair open Black wire (ground circuit) on fuel pump connector. Perform TEST VER-2A.
8. Turn ignition off. Using a ohmmeter, check resistance of PCM connector terminal No. 23 (Dark Blue wire). If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open Dark Blue wire from fuel pump connector to splice. Perform TEST VER-2A.

TEST TC-150B - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Turn ignition on. Using a voltmeter, check voltage on PCM connector terminal No. 23 low fuel sense circuit (Yellow/Blue wire). If voltage is 4.7 volts or less, go to next step. If voltage is more than 4.7 volts, go to step 6).
2. If voltage is .5 volt or less, go to next step. If voltage is more than .5 volt, replace PCM. Perform TEST VER-2A.
3. While observing voltmeter, wiggle wiring harness for fuel level sending unit. If voltage changed, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If voltage did not change, go to next step.
4. Condition to set trouble code is not present at this time. FUEL LEVEL SENDING UNIT VOLTS TOO HIGH DTC sets if PCM terminal No. 23 fuel level sensor signal circuit voltage goes more than a calculated value. Possible causes are: open fuel level sensor signal circuit, failed fuel level sending unit, instrument cluster printed circuit board failure or failed PCM. Go to next step.
5. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.
6. Disconnect fuel level sending unit connector. Fuel level sending unit connector is located under right side of rear seat. Connect a jumper wire between Yellow/Blue wire and Black wire at fuel level sending unit connector (harness side). Using a voltmeter, check voltage of PCM connector terminal No. 23 (Yellow/Blue wire). If voltage is 4.7 volts or more, go to next step. If voltage is less than 4.7 volts, replace fuel level sending unit. Perform TEST VER-2A.
7. Disconnect jumper wire. Reconnect jumper wire to chassis ground. Using a voltmeter, check voltage of PCM connector terminal No. 23 (Yellow/Blue wire). If voltage is 4.7 volts or more, repair open low fuel sense circuit (Yellow/Blue wire). Perform TEST VER-2A. If voltage is less than 4.7 volts, repair open Black wire (ground circuit) on fuel level sending unit connector. Perform TEST VER-2A.

TEST TC-151A - FUEL LEVEL UNIT NO CHANGE OVER MILES

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Ensure fuel tank is at least 1/4 full. Go to TEST TC-151B. Fuel pump connector is located at fuel tank. Turn ignition on. If fuel gauge in instrument cluster reads empty, go to next step. If fuel gauge in instrument cluster does not read empty, repair short to ground on fuel level sensor signal circuit Dark Blue wire. Perform TEST VER-2A.
2. Using a voltmeter, check voltage of fuel level sensor signal circuit at fuel pump connector (harness side) Dark Blue wire. If voltage is more than 9 volts, go to next step. If voltage is 9 volts or less, go to step 5).
3. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Turn ignition on. Using a voltmeter, check voltage of fuel level sensor signal circuit at PCM connector terminal No. 23 (Dark Blue wire). If voltage is more than 9 volts, go to next step. If voltage is 9 volts or less, repair open Dark Blue wire. Perform TEST VER-2A.
4. Remove fuel pump module from fuel tank. Remove fuel level sending unit from fuel pump module. Inspect fuel level sending unit for proper operation. If fuel tank sending unit is okay, replace PCM. Perform TEST VER-2A. If fuel tank sending unit is not okay, replace fuel tank sending unit. Perform TEST VER-2A.
5. Turn ignition off. Remove instrument cluster. Using a voltmeter, check voltage on right instrument cluster connector terminal No. 5 (Dark Blue/White wire). see scheme 64 If voltage is more than 9 volts, go to next step. If voltage is 9 volt or less, repair open Dark Blue/White wire. Perform TEST VER-2A. see scheme 64: Identifying Right Instrument Cluster Connector
6. Turn ignition off. Connect a jumper wire between left instrument cluster connector terminal No. 10 (Dark Blue wire) and ground. see scheme 65 Using an ohmmeter, check resistance of fuel level sensor signal circuit (Dark Blue wire) at fuel pump harness connector (at fuel tank). If resistance is less than 5 ohms, replace instrument cluster printed circuit board. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open circuit between left instrument cluster connector and 4-pin fuel pump harness connector (at fuel tank). Perform TEST VER-2A. see scheme 65: Identifying Left Instrument Cluster Connector

TEST TC-151B - FUEL LEVEL UNIT NO CHANGE OVER MILES

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Ensure fuel tank is at least 1/4 full. If fuel gauge reads more than 1/8 tank and low fuel light is on, replace fuel level sending unit. Perform TEST VER-2A. If fuel gauge does not read more than 1/8 tank and low fuel light is not on, go to next step.
2. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Turn ignition on. Using a voltmeter, check voltage of PCM connector terminal No. 23 (Yellow/Dark Blue wire). If voltage is .5-4.7 volts, go to next step. If voltage is not .5-4.7 volts, replace fuel level sending unit. Perform TEST VER-2A.
3. Remove fuel level sending unit from fuel tank. Inspect fuel level sending unit for proper operation. If fuel tank sending unit is okay, replace PCM. Perform TEST VER-2A. If fuel tank sending unit is not okay, replace fuel tank sending unit. Perform TEST VER-2A.

TEST TC-152A - BRAKE SWITCH SENSE CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect brake switch connector. Turn ignition on. Using a voltmeter, check voltage of brake switch sense circuit at brake switch connector. See BRAKE SWITCH CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 9 volts, go to next step. If voltage is 9 volts or less, go to step 4).
2. Observe brake switch status on scan tool. Connect a jumper wire from brake switch sense circuit to ground. If scan tool display changed from PRESSED to RELEASED, replace brake switch. Perform TEST VER-2A. If scan tool display did not change, go to next step.
3. Using a ohmmeter, check resistance of ground circuit at brake switch connector. See BRAKE SWITCH CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open ground circuit. Perform TEST VER-2A.
4. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for pushed out terminals or damage. Repair PCM connector as necessary. Perform TEST VER-2A. If PCM connector is okay, go to next step.
5. Using a ohmmeter, check resistance of brake switch sense circuit between PCM connector terminals No. 50 and 62. See PCM CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open brake switch sense circuit. Perform TEST VER-2A.
6. Using a ohmmeter, check resistance of brake switch sense circuit at PCM connector terminal No. 62. See PCM CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, repair short to ground on brake switch sense circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-2A.

BRAKE SWITCH CONNECTOR WIRE IDENTIFICATION

PCM CONNECTOR WIRE IDENTIFICATION

TEST TC-153C - BATTERY TEMP SENSOR VOLTAGE TOO LOW OR BATTERY TEMP SENSOR VOLTAGE TOO HIGH

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, read Diagnostic Trouble Codes (DTCs). If BATTERY TEMPERATURE SENSOR VOLTAGE DTC is displayed with a run count of zero, replace Powertrain Control Module (PCM). Perform TEST VER-2A. If BATTERY TEMPERATURE SENSOR VOLTAGE DTC is not displayed with a run count of zero, go to next step.
2. Condition to set trouble code is not present at this time. BATTERY TEMP SENSOR VOLTAGE TOO LOW OR TOO HIGH DTC sets if BTS voltage is less than .5 volt or more than 4.9 volts for 3 seconds. Possible causes are: PCM failure or poor connections. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A.

TEST TC-155A - O2S 1/1 VOLTAGE SHORTED TO GROUND

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/1 IDENTIFICATION table. O2S 1/1 VOLTAGE SHORTED TO GROUND DTC sets if O2S 1/1 signal voltage is less than .156 volt for 28 seconds after engine start. Possible causes are: O2S 1/1 output wire shorted to another circuit, dirty or wet O2S 1/1 connector causing voltage tracking, O2S1/1 failure or Powertrain Control Module (PCM) failure. Go to next step. O2 SENSOR 1/1 IDENTIFICATION Application Location 2.5L Rear Bank Upstream O2S
2. Turn ignition on. Using scan tool, observe O2S 1/1 voltage for a few minutes. If O2S 1/1 voltage is less than .16 volt, go to next step. If O2S 1/1 voltage is .16 volt or more, condition to set trouble code is not present at this time. Perform TEST VER-5A.
3. Turn ignition off. Disconnect O2S 1/1 connector. Turn ignition on. Using scan tool, read O2S 1/1 voltage. If voltage is less than .16 volt, go to next step. If voltage is .16 volt or more, replace O2S 1/1. Perform TEST VER-5A.
4. Turn ignition off. Disconnect PCM connector. Using an ohmmeter, check resistance between O2S 1/1 signal circuit and O2S 1/1 ground circuit at O2S 1/1 connector (harness side). See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground circuit on O2S 1/1 signal circuit. Perform TEST VER-5A.
5. Using an ohmmeter, check resistance between O2S 1/1 signal circuit and chassis ground at O2S 1/1 connector (harness side). See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-5A. If resistance is less than 5 ohms, repair short to ground on O2S 1/1 signal circuit. Perform TEST VER-5A.

O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-156A - O2S 1/2 VOLTAGE SHORTED TO GROUND

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/2 IDENTIFICATION table. O2S 1/1 VOLTAGE SHORTED TO GROUND DTC sets if O2S 1/2 signal voltage is less than .156 volt for 28 seconds after engine start. Possible causes are: O2S 1/2 output wire shorted to another circuit, dirty or wet O2S 1/2 connector causing voltage tracking, O2S1/2 failure or Powertrain Control Module (PCM) failure. Go to next step. O2 SENSOR 1/2 IDENTIFICATION Application Location 2.5L Rear Bank Downstream O2S
2. Turn ignition on. Using scan tool, observe O2S 1/2 voltage for a few minutes. If O2S 1/2 voltage is less than .16 volt, go to next step. If O2S 1/2 voltage is .16 volt or more, condition to set trouble code is not present at this time. Perform TEST VER-5A.
3. Turn ignition off. Disconnect O2S 1/2 connector. Turn ignition on. Using scan tool, read O2S 1/2 voltage. If voltage is less than .16 volt, go to next step. If voltage is .16 volt or more, replace O2S 1/2. Perform TEST VER-5A.
4. Turn ignition off. Disconnect PCM connector. Using an ohmmeter, check resistance of O2S 1/2 signal circuit at O2S 1/2 connector (harness side). See O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, repair short to ground on O2S 1/2 signal circuit. Perform TEST VER-5A. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-5A.

O2S 1/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-157A - INTERMITTENT LOSS OF CMP OR CKP

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Camshaft Position (CMP) sensor or Crankshaft Position (CKP) sensor signal loss can be detected by a pattern on an oscilloscope. If this trouble code is being diagnosed with an oscilloscope, go to next step. If this trouble code is not being diagnosed with an oscilloscope, go to TEST TC-157B.
2. Using oscilloscope voltage lead, backprobe CMP sensor signal circuit at CMP sensor connector. Start engine. Observe CMP sensor voltage pattern on oscilloscope. If any CMP sensor signals are missing, go to next step. If any CMP sensor signals are not missing, go to step 6).
3. Turn ignition off. Disconnect CMP sensor connector. Inspect CMP sensor connector for pushed out terminals or damage. Repair CMP sensor connector as necessary. Perform TEST VER-2A. If CMP sensor is okay, go to next step.
4. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for pushed out terminals or damage. Repair PCM connector as necessary. Perform TEST VER-2A. If PCM connector is okay, replace CMP sensor. Perform TEST VER-2A.
5. Remove CMP sensor. Inspect pulse ring and sprocket for damage or misalignment. Repair or replace as necessary. Perform TEST VER-2A. If pulse ring and sprocket are okay, replace CMP sensor. Perform TEST VER-2A.
6. Using oscilloscope voltage lead, backprobe CMP sensor signal circuit at PCM connector terminal No. 33. See PCM CONNECTOR WIRE IDENTIFICATION table. While observing oscilloscope pattern, wiggle wiring harness from CMP sensor connector to PCM connector. If any signals were missing when wiring harness was wiggled, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If signals were not missing when wiring harness was wiggled, go to next step.
7. Turn ignition off. Using oscilloscope voltage lead, backprobe CKP sensor signal circuit. See CKP SENSOR CONNECTOR WIRE IDENTIFICATION table. Start engine. Observe CKP sensor voltage pattern on oscilloscope. If any CKP sensor signals are missing, go to next step. If any CMP sensor signals are not missing, go to step 10).
8. Turn ignition off. Disconnect CKP sensor connector. Inspect CKP sensor connector for pushed out terminals or damage. Repair CKP sensor connector as necessary. Perform TEST VER-2A. If CKP sensor is okay, go to next step.
9. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for pushed out terminals or damage. Repair PCM connector as necessary. Perform TEST VER-2A. If PCM connector is okay, replace CKP sensor. Perform TEST VER-2A.
10. Using oscilloscope voltage lead, backprobe CKP sensor signal circuit at PCM connector terminal No. 32. See PCM CONNECTOR WIRE IDENTIFICATION table. While observing oscilloscope pattern, wiggle wiring harness from CKP sensor connector to PCM connector. If any signals were missing when wiring harness was wiggled, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If signals were not missing when wiring harness was wiggled, go to next step.
11. Condition to set trouble code is not present at this time. INTERMITTENT LOSS OF CMP OR CKP DTC sets if expected cam signal level disagrees with actual cam signal level. Possible causes are: open or shorted 8-volt supply circuit, open sensor ground, open or shorted signal circuit, excessive clearance between crankshaft sensor and crankshaft pulse ring, excessive clearance between camshaft sensor and target magnet, damaged target magnet, damaged crankshaft pulse ring, failed sensor or failed PCM. Go to next step.
12. Inspect all related wiring and connectors and repair as necessary. Perform TEST VER-2A. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.

CKP SENSOR CONNECTOR WIRE IDENTIFICATION

PCM CONNECTOR WIRE IDENTIFICATION

TEST TC-157B - INTERMITTENT LOSS OF CMP OR CKP

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for pushed out terminals or damage. Repair PCM connector as necessary. Perform TEST VER-2A. If PCM connector is okay, go to next step.
2. Disconnect CMP sensor connector. Inspect CMP sensor connector for pushed out terminals or damage. Repair CMP sensor connector as necessary. Perform TEST VER-2A. If CMP sensor is okay, go to next step.
3. Disconnect CKP sensor connector. Inspect CKP sensor connector for pushed out terminals or damage. Repair CKP sensor connector as necessary. Perform TEST VER-2A. If CKP sensor is okay, go to next step.
4. Reconnect CMP and CKP sensor connectors. Start engine and wait 30 seconds. Using scan tool, read trouble codes. If INTERMITTENT LOSS OF CMP OR CKP DTC is set, go to next step. If INTERMITTENT LOSS OF CMP OR CKP DTC is not set, go to TEST TC-157C.
5. If CMP sensor was just replaced, turn ignition off. Replace CKP sensor. Perform TEST VER-2A. If CMP sensor was not just replaced, turn engine off. Replace CMP sensor. Using scan tool, erase trouble codes. Repeat steps 4) and 5).

TEST TC-157C - INTERMITTENT LOSS OF CMP OR CKP

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. If CMP sensor was just replaced, test is complete. Perform TEST VER-2A. If CMP sensor was not just replaced, go to next step.
2. Using scan tool, read engine RPM while wiggling CMP and CKP sensor wiring harness. If engine RPM changes while wiggling wiring harness, repair wiring harness where wiggling caused problem to appear. Perform TEST VER-2A. If engine RPM does not change while wiggling wiring harness, go to next step.
3. Using scan tool, read trouble codes. If scan tool displays INTERMITTENT LOSS OF CMP OR CKP DTC, trouble code was reset due to wiggling wiring harness. Repair wiring harness where wiggling caused trouble code to set. Perform TEST VER-2A. If scan tool does not display INTERMITTENT LOSS OF CMP OR CKP DTC, go to next step.
4. No problem has been found. If more wiring harness wiggle testing is desired to find possible problem, go to step 2). If no more wiring harness wiggle testing is desired at this time, go to next step.
5. Condition to set trouble code is not present at this time. INTERMITTENT LOSS OF CMP OR CKP DTC sets if expected cam signal level disagrees with actual cam signal level. Possible causes are: open or shorted 8-volt supply circuit, open sensor ground, open or shorted signal circuit, excessive clearance between crankshaft sensor and crankshaft pulse ring, excessive clearance between camshaft sensor and target magnet, damaged target magnet, damaged crankshaft pulse ring, failed sensor or failed PCM. Go to next step.
6. Inspect all related wiring and connectors and repair as necessary. Perform TEST VER-2A. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.

TEST TC-160A - EVAP LEAK MONITOR SMALL LEAK DETECTED

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. A defective secondary seal in fuel filler neck or leaving fuel cap loose or off could set this trouble code. Connect a hand vacuum pump to Leak Detection Pump (LDP) Service Vacuum Supply Tee (SVST). SVST is located in-line in direct vacuum supply hose to LDP. (Scheme 109) Using hand vacuum pump, apply 18 in. of vacuum to LDP. If hand vacuum pump holds vacuum, go to next step. If hand vacuum pump does not hold vacuum, inspect vacuum hoses for damage. Repair vacuum hoses as necessary. Perform TEST VER-5A. If vacuum hoses are okay, replace LDP. Perform TEST TC-160A to verify repair.
2. Turn ignition on. Using scan tool, actuate LDP. Observe vacuum gauge on hand held vacuum pump. If vacuum drops, go to next step. If vacuum does not drop, replace LDP. Perform TEST TC-160A to verify repair.
3. To continue and properly diagnose this trouble code, Miller Tool Kit (6872A) is necessary. Perform evaporative system pressure pump self-test specified on cover of tool kit. Go to next step.
4. Connect EVAP pressure pump supply hose to EVAP system test port. (Scheme 109) Start engine. Using scan tool in LDP SYSTEM TEST, press key No. 3 to hold. Disconnect purge solenoid. Set pressure hold to OPEN position and set vent to CLOSED position. Turn pump timer on. Go to next step.
5. Perform IM240 simulation described on cover of Tool Kit (6872A) while scan tool is still in LDP SYSTEM TEST. If pressure drops more than 8 in. of water vacuum in 2 minutes, go to step 7). If pressure does not drop more than 8 in. of water vacuum in 2 minutes, go to next step.
6. Inspect all related wiring, connectors and hoses and repair as necessary. Perform TEST VER-5A. If no problems were found with wiring, connectors and hoses, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-5A.
7. To continue test, Ultrasonic Leak Detector (6904) is necessary. While scan tool is still in LDP SYSTEM TEST, set pressure hold to OPEN and set vent to OPEN position. Turn pump timer on. Move Miller Tool Kit (6872A) away from vehicle to prevent operating noise from interfering with testing procedure.
8. Using ultrasonic leak detector, start listening for leaks at fuel cap, fuel tank rollover valve, EVAP canister, LDP and EVAP solenoid. If any leaks are heard with ultrasonic leak detector, repair or replace leaking component. Perform TEST VER-5A. If no leaks are heard with ultrasonic leak detector, replace LDP. Perform TEST VER-5A.

Locating EVAP System Test Port & Service Vacuum Supply Tee (SVST). Scheme 109

TEST TC-161A - EVAP LEAK MONITOR LARGE LEAK DETECTED

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. A defective secondary seal in fuel filler neck or leaving fuel cap loose or off could set this trouble code. Connect a hand vacuum pump to Leak Detection Pump (LDP) Service Vacuum Supply Tee (SVST). SVST is located in-line in direct vacuum supply hose to LDP. see scheme 67 Using hand vacuum pump, apply 18 in. Hg of vacuum to LDP. If hand vacuum pump holds vacuum, go to next step. If hand vacuum pump does not hold vacuum, inspect vacuum hoses for damage. Repair vacuum hoses as necessary. Perform TEST VER-5A. If vacuum hoses are okay, replace LDP. Perform TEST TC-160A to verify repair.
2. Turn ignition on. Using scan tool, actuate LDP. Observe vacuum gauge on hand held vacuum pump. If vacuum drops, go to next step. If vacuum does not drop, replace LDP. Perform TEST TC-160A to verify repair.
3. To continue and properly diagnose this trouble code, Miller Tool Kit (6872A) is necessary. Perform evaporative system pressure pump self-test specified on cover of tool kit. Go to next step.
4. Connect EVAP pressure pump supply hose to EVAP system test port. see scheme 67 Start engine. Using scan tool in LDP SYSTEM TEST, press key No. 3 to hold. Disconnect purge solenoid. Set pressure hold to OPEN position and set vent to CLOSED position. Turn pump timer on. Go to next step.
5. Perform IM240 simulation described on cover of Miller Tool Kit (6872A) while scan tool is still in LDP SYSTEM TEST. If pressure drops more than 8 in. of water vacuum in 2 minutes, go to step 7). If pressure does not drop more than 8 in. of water vacuum in 2 minutes, go to next step.
6. Inspect all related wiring, connectors and hoses and repair as necessary. Perform TEST VER-5A. If no problems were found with wiring, connectors and hoses, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-5A.
7. To continue test, Ultrasonic Leak Detector (6904) is necessary. Set pressure hold to OPEN and set vent to CLOSED position. Turn pump timer on. Move Miller Tool Kit (6872A) away from vehicle to prevent operating noise from interfering with testing procedure.
8. If operating noise still interferes with test, set pressure hold to CLOSED and turn pump timer off. EVAP system must be able to hold pressure to detect a leak. If EVAP system cannot hold pressure, leave pump timer on and set pressure hold to OPEN. Using ultrasonic leak detector, start listening for leaks at fuel cap, fuel tank rollover valve, EVAP canister, LDP and EVAP solenoid. If any leaks are heard with ultrasonic leak detector, repair or replace leaking component. Perform TEST VER-5A. If no leaks are heard with ultrasonic leak detector, replace LDP and filter. Perform TEST VER-5A.

TEST TC-180A - CATALYST 2/1 EFFICIENCY FAILURE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Repair any O2S related Diagnostic Trouble Codes (DTCs) before proceeding with this test. If no O2S related DTCs are set, check for any Technical Service Bulletins (TSBs) which may apply. If any TSBs are found to apply, perform TSB action as necessary. If no TSBs apply, go to next step.
2. CATALYST 2/1 EFFICIENCY FAILURE DTC sets as converter loses its ability to store oxygen. Efficiency drops and oxygen concentration becomes the same downstream as upstream. Output voltage of downstream O2S copies upstream O2S with a time lag seen by the Powertrain Control Module (PCM) between switching of O2S's. Malfunction Indicator Light (MIL) illuminates after 2 trips and remains on. MIL will go out if conditions that set trouble code are not found on 3 subsequent trips. Go to next step.
3. Start engine. Check exhaust system for leaks between engine and downstream O2S. If no exhaust leaks are found, go to next step. If exhaust leaks are found, repair or replace exhaust system parts as necessary. Perform TEST VER-5A.
4. Check exhaust gas for excessive smoke caused by oil consumption. If a high oil consumption condition is not present, go to next step. If a high oil consumption condition is present, repair engine for mechanical failure and replace catalytic converter. Perform TEST VER-5A.
5. A newly installed downstream O2S used with an existing (aging) upstream O2S may cause this trouble code to set. If downstream O2S has been replaced within the last 5000 miles, go to next step. If downstream O2S has not been replaced within the last 5000 miles, replace catalytic converter. Perform TEST VER-5A.
6. If upstream O2S has been replaced within the last 5000 miles, replace catalytic converter. Perform TEST VER-5A. If upstream O2S has not been replaced within the last 5000 miles, replace upstream O2S. Perform TEST VER-5A.

TEST TC-181A - O2S 2/1 SHORTED TO GROUND

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/1 IDENTIFICATION table. O2S 2/1 VOLTAGE SHORTED TO GROUND DTC sets if O2S 2/1 signal voltage is less than .156 volt for 28 seconds after engine start. Possible causes are: O2S 2/1 output wire shorted to another circuit, dirty or wet O2S 2/1 connector causing voltage tracking, O2S2/1 failure or Powertrain Control Module (PCM) failure. Go to next step. O2 SENSOR 2/1 IDENTIFICATION Application Location 2.5L Front Bank Upstream O2S
2. Turn ignition on. Using scan tool, observe O2S 2/1 voltage for a few minutes. If O2S 2/1 voltage is less than .16 volt, go to next step. If O2S 2/1 voltage is .16 volt or more, condition to set trouble code is not present at this time. Perform TEST VER-5A.
3. Turn ignition off. Disconnect O2S 2/1 connector. Turn ignition on. Using scan tool, read O2S 2/1 voltage. If voltage is less than .16 volt, go to next step. If voltage is .16 volt or more, replace O2S 2/1. Perform TEST VER-5A.
4. Turn ignition off. Disconnect PCM connector. Using an ohmmeter, check resistance between O2S 2/1 signal circuit and O2S 2/1 ground circuit at O2S 2/1 connector (harness side). See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground circuit on O2S 2/1 signal circuit. Perform TEST VER-5A.
5. Using an ohmmeter, check resistance between O2S 2/1 signal circuit and chassis ground at O2S 2/1 connector (harness side). See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-5A. If resistance is less than 5 ohms, repair short to ground on O2S 2/1 signal circuit. Perform TEST VER-5A.

O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-182A - O2S 2/2 SHORTED TO GROUND

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/2 IDENTIFICATION table. O2S 2/2 VOLTAGE SHORTED TO GROUND DTC sets if O2S 2/2 signal voltage is less than .156 volt for 28 seconds after engine start. Possible causes are: O2S 2/2 output wire shorted to another circuit, dirty or wet O2S 2/2 connector causing voltage tracking, O2S2/2 failure or Powertrain Control Module (PCM) failure. Go to next step. O2 SENSOR 2/2 IDENTIFICATION Application Location 2.5L Front Bank Downstream O2S
2. Turn ignition on. Using scan tool, observe O2S 2/2 voltage for a few minutes. If O2S 2/2 voltage is less than .16 volt, go to next step. If O2S 2/2 voltage is .16 volt or more, condition to set trouble code is not present at this time. Perform TEST VER-5A.
3. Turn ignition off. Disconnect O2S 2/2 connector. Turn ignition on. Using scan tool, read O2S 2/2 voltage. If voltage is less than .16 volt, go to next step. If voltage is .16 volt or more, replace O2S 2/2. Perform TEST VER-5A.
4. Turn ignition off. Disconnect PCM connector. Using an ohmmeter, check resistance between O2S 2/2 signal circuit and O2S 2/2 ground circuit at O2S 2/2 connector (harness side). See O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground circuit on O2S 2/2 signal circuit. Perform TEST VER-5A.
5. Using an ohmmeter, check resistance between O2S 2/2 signal circuit and chassis ground at O2S 2/2 connector (harness side). See O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or more, replace PCM. Perform TEST VER-5A. If resistance is less than 5 ohms, repair short to ground on O2S 2/2 signal circuit. Perform TEST VER-5A.

O2S 2/2 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-183A - LEAK DETECTION PUMP SOLENOID CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, actuate Leak Detection Pump (LDP) solenoid. If LDP solenoid is clicking, go to next step. If LDP solenoid is not clicking, go to step 5).
2. Using scan tool, stop actuation of LDP solenoid. Condition to set trouble code is not present at this time. LEAK DETECTION PUMP SOLENOID CIRCUIT DTC sets if solenoid state does not change. Possible causes are: open or shorted LDP solenoid control circuit, LDP solenoid failure or open fused ignition switch output. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-5A.
4. Using scan tool, actuate LDP solenoid. While listening to LDP solenoid, wiggle wiring harness from LDP solenoid to PCM connector. If LDP solenoid stopped clicking when wiggling wiring harness, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-5A. If LDP solenoid did not stop clicking when wiggling wiring harness, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-5A.
5. Turn ignition off. Disconnect LDP solenoid connector at leak detection pump. LDP solenoid is located on LDP. See LDP SOLENOID LOCATION table. Go to next step. LDP SOLENOID LOCATION Application Location FJ22 Body Behind Right Front Wheel Splash Shield
6. Turn ignition on. Using a voltmeter, check voltage of fused ignition switch output circuit at LDP solenoid connector. See LDP CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused ignition switch output circuit. Perform TEST VER-5A. LDP CONNECTOR WIRE IDENTIFICATION Application Wire Color LDP Fused Ignition Switch Output Circuit Black/White LDP Solenoid Control Circuit Red/Yellow
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of LDP solenoid control circuit between LDP solenoid connector and PCM connector terminal No. 77. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open LDP solenoid control circuit. Perform TEST VER-5A.
8. Using an ohmmeter, check resistance of PCM connector terminal No. 77 (LDP solenoid control circuit). See PCM CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on LDP solenoid control circuit. Perform TEST VER-5A.
9. Reconnect LDP solenoid connector. Turn ignition on. Using a voltmeter, check voltage of PCM connector terminal No. 77 (LDP solenoid control circuit). See PCM CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, replace PCM. Perform TEST VER-5A. If voltage is 10 volts or less, replace LDP. Perform TEST VER-5A.

PCM CONNECTOR WIRE IDENTIFICATION

TEST TC-184A - LEAK DETECTION PUMP SWITCH OR MECHANICAL FAULT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Start engine and allow to idle. Using scan tool, read Leak Detection Pump (LDP) switch state. Using scan tool, actuate LDP solenoid. With scan tool actuating LDP solenoid, observe LDP switch state.
2. If scan tool indicates LDP switch state toggled, go to next step. If scan tool does not indicate LDP switch state toggled, go to step 6).
3. Using scan tool, stop actuation of LDP solenoid. Condition to set trouble code is not present at this time. LEAK DETECTION PUMP SOLENOID CIRCUIT DTC sets if solenoid state does not change when solenoid is energized. Possible causes are: open or shorted LDP switch sense circuit, LDP switch failure or open fused ignition switch output circuit. Go to next step.
4. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-5A.
5. Using scan tool, actuate LDP solenoid. While monitoring LDP switch state, wiggle wiring harness from LDP solenoid to PCM connector. If LDP switch state stopped toggling when wiggling wiring harness, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-5A. If LDP switch state did not stop toggling when wiggling wiring harness, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-5A.
6. Turn ignition off. Disconnect vacuum supply line from LDP solenoid. See LDP SOLENOID LOCATION table. Go to next step. LDP SOLENOID LOCATION Application Location FJ22 Body Behind Right Front Wheel Splash Shield
7. Install a vacuum gauge to LDP vacuum supply hose. Start engine and observe vacuum gauge. If vacuum gauge indicates to within one in. Hg of engine vacuum, go to next step. If vacuum gauge does not indicate to within one in. Hg of engine vacuum, repair leak or obstruction in LDP solenoid vacuum supply hose. Perform TEST VER-5A.
8. Turn ignition off. Disconnect LDP solenoid connector. Turn ignition on. Using a voltmeter, check voltage of fused ignition switch output circuit at LDP solenoid connector. See LDP CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused ignition switch output circuit. Perform TEST VER-5A. LDP CONNECTOR WIRE IDENTIFICATION Application Wire Color LDP Fused Ignition Switch Output Circuit Black/White LDP Solenoid Control Circuit Red/Yellow
9. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of LDP switch sense circuit between LDP solenoid connector and PCM connector terminal No. 72. See LDP CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open LDP switch sense circuit. Perform TEST VER-5A.
10. Using an ohmmeter, check resistance of PCM connector terminal No. 72 (LDP switch sense circuit). See PCM CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on LDP switch sense circuit. Perform TEST VER-5A. PCM CONNECTOR WIRE IDENTIFICATION Application Wire Color PCM Terminal No. 72 (LDP Switch Sense Circuit) Red/Dark Blue
11. Reconnect LDP solenoid connector. Turn ignition on. Using a voltmeter, check voltage of PCM connector terminal No. 72 (LDP switch sense circuit). See PCM CONNECTOR WIRE IDENTIFICATION table. Using a hand vacuum pump, apply vacuum to LDP and observe voltmeter. If voltage changed, replace PCM. Perform TEST VER-5A. If voltage did not change, replace LDP. Perform TEST VER-5A.

TEST TC-186A - MISFIRE ADAPTIVE NUMERATOR AT LIMIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. This trouble code will set if one of the Crankshaft Position (CKP) sensor target windows (40 degrees) has more than 2.86 percent variance from reference the window. Possible causes are: CKP sensor improperly installed, CKP sensor failure, CKP sensor crankshaft target variation, severely worn crankshaft bearings, PCM failure or low compression in one or more cylinders. Go to next step.
2. Turn ignition off. Disconnect connector at Crankshaft Position (CKP) sensor. Inspect CKP sensor connector for pushed out terminals or damage. Repair CKP sensor connector as necessary. Perform TEST VER-2A. If CKP sensor is okay, go to next step.
3. Inspect Crankshaft Position (CKP) sensor for proper installation. If CKP sensor is properly installed, go to next step. If CKP sensor is not properly installed, properly install CKP sensor. Perform TEST VER-2A.
4. Remove CKP sensor. Go to next step.
5. If damage or excessive movement of either component is found, repair component failure as necessary. Perform TEST VER-2A. If damage or excessive movement of either component is not found, replace CKP sensor. Perform TEST VER-2A.

TEST TC-187A - EVAP LEAK MONITOR PINCHED HOSE

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. To properly diagnose this trouble code, Miller Tool Kit (6872A) is necessary. Perform evaporative system pressure pump self-test specified on cover of tool kit.
2. Connect EVAP pressure pump supply hose to EVAP system test port. see scheme 68 Start engine. Using scan tool in LDP SYSTEM TEST, follow instructions displayed on screen. Set pressure hold to OPEN position and set vent to CLOSED position. Turn pump timer on. Go to next step.
3. Allow pressure on Miller Tool Kit (6872) to build to at least 14 in. of water vacuum. Remove gas cap. If pressure dropped when gas cap was removed, go to next step. If pressure did not drop when gas cap was removed, go to step 5).
4. Reinstall gas cap and allow pressure to build up to at least 14 in. of water vacuum. Disconnect LDP hose from LDP. If pressure dropped when hose was disconnected, replace LDP. Perform TEST VER-5A. If pressure did not drop when hose was disconnected, replace evaporative canister. Perform TEST VER-5A.
5. Reinstall gas cap. Allow pressure to build to at least 14 in. of water vacuum. Remove fuel tank rollover hose from EVAP canister. If pressure did not drop when hose was disconnected, go to next step. If pressure dropped when hose was disconnected, repair pinched hose from fuel tank to EVAP canister. Perform TEST VER-5A.
6. Disconnect EVAP purge line at EVAP canister. If pressure dropped when hose was disconnected, replace EVAP canister. Perform TEST VER-5A. If pressure did not drop when hose was disconnected, repair obstruction in EVAP purge line to EVAP canister. Perform TEST VER-5A.

TEST TC-192A - SLOW O2S 1/1 DURING CATALYST MONITOR

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 1/1 IDENTIFICATION table. This trouble code will set when upstream O2S signal voltage is switching from less than .39 volt to more than .60 volt and back fewer times than required. Possible causes are: exhaust leak, fuel contamination, weak upstream O2S with deteriorated catalyst, dirty or wet O2S 1/1 connector or engine mechanical failure. Go to next step. O2 SENSOR 1/1 IDENTIFICATION Application Location 2.5L Rear Bank Upstream O2S
2. Start engine. Inspect exhaust system for leaks between engine and catalytic converter(s). If exhaust leaks are not present, go to next step. If exhaust leaks are present, repair or replace exhaust system as necessary. Perform TEST VER-5A.
3. Inspect exhaust system for excessive smoke caused by oil or coolant consumption. If an oil or coolant consumption condition is not present, go to next step. If an oil or coolant consumption condition is present, repair engine as necessary and replace O2S 1/1. Perform TEST VER-5A.
4. Turn ignition off. Disconnect O2S 1/1 connector. Inspect O2S 1/1 connector for pushed out terminals or damage. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
5. Using an ohmmeter, check resistance between O2S 1/1 sensor ground circuit and chassis ground at O2S 1/1 connector (harness side). See O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or more, repair open O2S 1/1 sensor ground circuit. Perform TEST VER-5A. If resistance is less than 5 ohms, go to next step.
6. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for pushed out terminals or damage. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, replace O2S 1/1. Perform TEST VER-5A.

O2S 1/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-193A - SLOW O2S 2/1 DURING CATALYST MONITOR

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. For O2 sensor/model identification see O2 SENSOR 2/1 IDENTIFICATION table. This trouble code will set when upstream O2S signal voltage is switching from less than .39 volt to more than .60 volt and back fewer times than required. Possible causes are: exhaust leak, fuel contamination, weak upstream O2S with deteriorated catalyst, dirty or wet O2S 2/1 connector or engine mechanical failure. Go to next step. O2 SENSOR 2/1 IDENTIFICATION Application Location 2.5L Front Bank Upstream O2S
2. Start engine. Inspect exhaust system for leaks between engine and catalytic converter(s). If exhaust leaks are not present, go to next step. If exhaust leaks are present, repair or replace exhaust system as necessary. Perform TEST VER-5A.
3. Inspect exhaust system for excessive smoke caused by oil or coolant consumption. If an oil or coolant consumption condition is not present, go to next step. If an oil or coolant consumption condition is present, repair engine as necessary and replace O2S 2/1. Perform TEST VER-5A.
4. Turn ignition off. Disconnect O2S 2/1 connector. Inspect O2S 2/1 connector for pushed out terminals or damage. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, go to next step.
5. Using an ohmmeter, check resistance between O2S 2/1 sensor ground circuit and chassis ground at O2S 2/1 connector (harness side). See O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is 5 ohms or more, repair open O2S 2/1 sensor ground circuit. Perform TEST VER-5A. If resistance is less than 5 ohms, go to next step.
6. Disconnect Powertrain Control Module (PCM) connector. Inspect PCM connector for pushed out terminals or damage. Repair connector as necessary. Perform TEST VER-5A. If connector is okay, replace O2S 2/1. Perform TEST VER-5A.

O2S 2/1 CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST TC-197A - HIGH SPEED RADIATOR FAN GROUND CONTROL RELAY CIRCUIT

Note. For connector terminal ID, see CONNECTOR IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS - 2.5L article.

1. Using scan tool, actuate high speed fan ground relay. High speed fan ground relay is located in Power Distribution Center (PDC). If high speed fan ground relay is clicking, go to next step. If high speed fan ground relay is not clicking, go to step 5).
2. Condition to set trouble code is not present at this time. HIGH SPEED RADIATOR FAN GROUND CONTROL RELAY CIRCUIT DTC sets if an open or shorted condition is detected in high speed fan relay control circuit. Possible causes are: high speed fan relay coil open or shorted, fused ignition switch output circuit open, high speed fan relay control circuit open or shorted or inoperative circuit driver in Powertrain Control Module (PCM). Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, go to next step. If related wiring and connectors were repaired, perform TEST VER-2A.
4. With actuator test still running, wiggle wiring harness between high speed fan ground relay and PCM. High speed fan ground relay is located in Power Distribution Center (PDC). If wiggling caused an interruption in high speed fan ground relay clicking, repair wiring harness as necessary where wiggling caused problem to appear. Perform TEST VER-2A. If wiggling did not cause an interruption in high speed fan ground relay clicking, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A.
5. Disconnect high speed fan ground relay. High speed fan ground relay is located in Power Distribution Center (PDC). Using a voltmeter, check voltage of ignition switch output circuit at high speed fan ground relay connector. see scheme 69 If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ignition switch output circuit. Perform TEST VER-2A. see scheme 69: Identifying High Speed Fan Ground Relay Connector Terminals & Location see scheme 70: Testing Relay
6. Using an ohmmeter, check resistance between high speed fan ground relay terminals. see scheme 70 If resistance is less than 100 ohms, go to next step. If resistance is 100 ohms or more, replace high speed fan ground relay. Perform TEST VER-2A.
7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of high speed fan ground relay control circuit at high speed fan relay connector. see scheme 69for terminal identification. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground in high speed fan relay control circuit. Perform TEST VER-2A.
8. Using an ohmmeter, measure resistance of high speed fan ground relay control circuit between high speed fan ground relay connector and PCM connector terminal No. 28. see scheme 69for wire identification. If resistance is less than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open high speed fan relay control circuit. Perform TEST VER-2A.

No Trouble Code Complete Test

Check Technical Service Bulletins (TSBs) for any pertinent information. If a TSB exists, perform corrective procedure as instructed. If no TSB exists or if problem still exists, perform test NTC-2A through NTC-18A in sequence until problem is found. See NO TROUBLE CODE TEST MENU table.

NO TROUBLE CODE TEST MENU

No Trouble Code Quick Individual Test

If any item listed in NO TROUBLE CODE TEST MENU table is suspected as cause of the driveability problem, perform associated test(s) individually. Return to NO TROUBLE CODE TEST MENU table if driveability problem still exists.

No Trouble Code Quick Symptom Test

Symptom checks cannot be used properly unless driveability problem occurs while vehicle is being tested. To reduce diagnostic time, ensure DTC TEST is reviewed before attempting to diagnosis a symptom. Select symptom which most accurately describes the driveability problem, and then perform test pertaining to the symptom. Perform each test in sequence until problem is found. See NO TROUBLE CODE QUICK SYMPTOM TEST MENU table.

NO TROUBLE CODE QUICK SYMPTOM TEST MENU

TEST NTC-2A - CHECKING SECONDARY IGNITION & TIMING

Note. Perform TEST NTC-1A before proceeding.

1. Turn engine off. Connect engine analyzer to engine. Start engine, and let it idle. If engine will not idle, maintain engine speed for reading scope pattern. Set scope to read display or parade pattern. Follow equipment manufacturer's procedure for pattern analysis.
2. If secondary ignition pattern is not okay, repair indicated component in secondary ignition system. Perform TEST VER-2A. If secondary ignition pattern is okay, momentarily disconnect each spark plug wire one at a time from distributor. Observe secondary kilovolt line.
3. If open circuit secondary voltage is not at least 25 kilovolts, replace electronic ignition coil. Perform TEST VER-2A. If open circuit secondary voltage is at least 25 kilovolts, go to next step.
4. Using scan tool, read total ignition timing advance. Increase engine speed to 2000 RPM. If ignition timing advance does not change with increase in engine RPM, replace Powertrain Control Module (PCM). Perform TEST VER-2A. If ignition timing advance changes with increase in engine speed, secondary ignition system and ignition timing advance are normal. Test is complete.

TEST NTC-3A - CHECKING FUEL PRESSURE

Note. Perform TEST NTC-1A or NTC-2A before proceeding.

1. Turn ignition off. Release fuel pressure. Connect Fuel Pressure Adapter (MD-998742) to fuel rail (if necessary). Connect fuel pressure gauge to fuel rail. Turn ignition on. Go to next step.
2. Using scan tool, actuate ASD fuel system. Observe and record fuel pressure. See FUEL PRESSURE SPECIFICATION table. If fuel pressure is not within specification, go to next step. If fuel pressure is within specification, perform TEST NTC-3B.
3. If fuel pressure is more than specification, perform TEST NS-4B. If fuel pressure is less than specification, perform TEST NS-4A.

FUEL PRESSURE SPECIFICATION

TEST NTC-3B - CHECKING FUEL PRESSURE

Note. Perform TEST NTC-3A before proceeding.

1. Using scan tool, stop ASD fuel system actuation. Apply parking brake. Place shift lever in Neutral. Start engine. While monitoring fuel pressure gauge, momentarily snap throttle wide open increasing engine speed to more than 3000 RPM.
2. If fuel pressure dropped to less than 35 psi (2.5 kg/cm 2 ) at all, fuel pressure is normal. Test is complete. If fuel pressure did not drop to less than 35 psi (2.5 kg/cm 2 ) at all, go to next step.
3. Place shift lever in Park. Turn ignition off. Inspect chassis fuel supply line for kinks or restrictions. If no kinks or restrictions exist in chassis fuel supply line, go to next step. If a kink or restriction exists in chassis fuel supply line, release fuel pressure and repair or replace chassis fuel supply line as necessary. Perform TEST VER-2A.
4. Release fuel pressure. Remove fuel pressure gauge. Remove fuel filter. Inspect fuel filter for restriction. If fuel filter is restricted, replace fuel filter. Perform TEST VER-2A. If fuel filter is not restricted, replace fuel pump and fuel filter. Perform TEST VER-2A.

TEST NTC-5A - CHECKING THROTTLE POSITION SENSOR

Note. Perform TEST NTC-1A or NTC-4A before proceeding.

1. Turn ignition off. Check throttle cable for binding. If vehicle is equipped with cruise control, also check cruise control cable for binding. If either cable is binding, repair as necessary. Perform TEST VER-2A. If either cable is not binding, go to next step.
2. Turn ignition on. Using scan tool, read Throttle Position (TP) sensor voltage. Ensure throttle is fully closed against throttle stop. If voltage is 1.5 volts or less, go to next step. If voltage is more than 1.5 volts, replace TP sensor. Perform TEST VER-2A.
3. Observe TP sensor voltage on scan tool while slowly opening throttle to Wide Open Throttle (WOT). If voltage change was smooth, go to next step. If voltage change was not smooth, replace TP sensor. Perform TEST VER-2A.
4. If voltage was at least 3.4 volts at WOT, TP sensor is functioning properly. Test is complete. If voltage was not at least 3.4 volts at WOT, replace TP sensor. Perform TEST VER-2A.

TEST NTC-6A - CHECKING MAP SENSOR

Note. Perform TEST NTC-1A or NTC-5A before proceeding.

Turn engine off. Tee a vacuum gauge to a manifold vacuum source. Start engine. Allow engine to idle. If engine will not idle, maintain a constant RPM above idle. Using scan tool, read Manifold Absolute Pressure (MAP) sensor vacuum. If scan tool vacuum reading is within one in. Hg of vacuum gauge reading, MAP sensor is functioning properly. Test is complete. If scan tool vacuum reading is not within one in. Hg of vacuum gauge reading, replace MAP sensor. Perform TEST VER-2A.

TEST NTC-7A - CHECKING OXYGEN SENSOR SWITCHING

Note. Perform TEST NTC-1A or NTC-6A before proceeding.

Note. During first step, observe downstream O2S voltage does not switch like upstream O2S voltage.

1. Start engine. Allow engine to reach normal operating temperature of 180°F (82°C). Using scan tool, read O2S signal voltages for 10 or more seconds. If O2S signal voltages are switching normally, O2 sensors are functioning normally. Test is complete. If O2S signal voltages are not switching normally, go to next step.
2. If upstream O2S state is locked on LEAN, go to TEST NTC-7B. If upstream O2S state is not locked on LEAN, turn ignition off. Release fuel pressure. Install a fuel pressure gauge to fuel rail. Turn ignition on. Using scan tool, actuate ASD fuel system test. Allow fuel pressure gauge to stabilize. Go to next step.
3. Using scan tool, stop ASD fuel system actuation. Observe fuel pressure gauge for one minute. If fuel pressure is less than 10 psi (0.7 kg/cm 2 ), replace leaking injector(s) as necessary. Perform TEST VER-2A. If fuel pressure is 10 psi (0.7 kg/cm 2 ) or more, go to next step.
4. Inspect air filter and inlet ducts for restrictions. If restrictions are present, clean inlet system as necessary. Perform TEST VER-2A. If restrictions are not present, go to TEST NTC-18A.

TEST NTC-7B - CHECKING OXYGEN SENSOR SWITCHING

Note. Perform NTC-7A before proceeding.

1. Start engine. Allow engine to idle. Inspect engine for any abnormal vacuum conditions which may indicate a possible engine mechanical problem. If abnormal vacuum conditions are present, repair engine as necessary. Perform TEST VER-2A. If abnormal vacuum conditions are not present, go to next step.
2. Using scan tool, read O2S signal voltages. If O2S signal voltage is .10 volt or more for either O2S, go to step 4). If O2S signal voltage is less than .10 volt for either O2S, go to next step.
3. Turn ignition off. Disconnect O2S connector that was less than .10 volt. For O2 sensor/model identification see O2 SENSOR IDENTIFICATION table. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of O2S signal circuit at O2S connector (harness side). See O2S CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, repair short to ground on O2S signal circuit. Perform TEST VER-2A. If resistance is 5 ohms or more, replace O2S. Perform TEST VER-2A. O2 SENSOR IDENTIFICATION Application Location O2S 1/1 Rear Bank Upstream O2S O2S 1/2 Rear Bank Downstream O2S O2S 2/1 Front Bank Upstream O2S O2S 2/2 Front Bank Downstream O2S
4. Using scan tool, reset adaptive fuel memory. Ensure engine is at normal operating temperature. Using scan tool, read O2S signal voltages for 10 or more seconds. If O2S signal voltages are switching normally, O2 sensors are functioning normally. Test is complete. If O2S signal voltages are not switching normally, go to TEST NTC-18A.

O2S CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE)

TEST NTC-8A - CHECKING OXYGEN SENSOR HEATER

Note. Perform NTC-1A or NTC-7A before proceeding.

1. For O2 sensor/model identification see O2 SENSOR IDENTIFICATION table. Turn ignition on. Using scan tool, actuate O2S heater test. Wait 2 minutes for O2S voltages to stabilize. Using scan tool, read upstream O2S voltage(s). If upstream voltage(s) is .4-.6 volt, go to next step. If upstream voltage(s) is not .4-.6 volt, go to step 4). O2 SENSOR IDENTIFICATION Application Location O2S 1/1 Rear Bank Upstream O2S O2S 1/2 Rear Bank Downstream O2S O2S 2/1 Front Bank Upstream O2S O2S 2/2 Front Bank Downstream O2S
2. When upstream voltage(s) stays .4-.6 volt, this indicates a problem with an O2S circuit. Ensure scan tool is still actuating O2S heater test. Disconnect upstream O2S connector. Using a voltmeter, check voltage of ASD relay output circuit at O2S connector (harness side). See O2S CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open circuit from upstream O2S connector (harness side) to splice. Perform TEST VER-2A.
3. Using scan tool, stop O2S heater test. Using an ohmmeter, check resistance of heater ground circuit at upstream O2S connector (harness side). See O2S CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, replace appropriate upstream O2S. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open heater ground circuit to appropriate upstream O2S. Perform TEST VER-2A. O2S CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) Application Wire Color O2S 1/1 ASD Relay Output Circuit Black/Red O2S 1/1 Heater Ground Circuit Black O2S 1/2 ASD Relay Output Circuit Black/Red O2S 1/2 Heater Ground Circuit Black O2S 2/1 Sensor Signal Circuit Black/Dark Green O2S 2/1 Sensor Ground Circuit Black/Dark Green O2S 2/2 Sensor Signal Circuit White/Red O2S 2/2 Sensor Ground Circuit Black/Dark Green
4. With scan tool still actuating O2S heater test, using scan tool, read downstream O2S voltage(s). If downstream voltage(s) is .4-.6 volt, go to next step. If downstream voltage(s) is not .4-.6 volt, O2S heater(s) is functioning properly. Using scan tool, stop O2S heater test. O2 sensors are functioning normally. Test is complete.
5. When downstream voltage(s) stays .4-.6 volt, this indicates a problem with an O2S circuit. Ensure scan tool is still actuating O2S heater test. Disconnect downstream O2S connector, disconnect each side separately). Using a voltmeter, check voltage of ASD relay output circuit at O2S connector (harness side). See O2S CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open circuit from downstream O2S connector (harness side) to splice. Perform TEST VER-2A.
6. Using scan tool, stop O2S heater test. Using an ohmmeter, check resistance of heater ground circuit at downstream O2S connector (harness side). See O2S CONNECTOR WIRE IDENTIFICATION (HARNESS SIDE) table. If resistance is less than 5 ohms, replace appropriate downstream O2S. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open heater ground circuit to appropriate downstream O2S. Perform TEST VER-2A.

TEST NTC-9A - CHECKING IDLE AIR CONTROL MOTOR

Note. Perform NTC-1A or NTC-8A before proceeding.

1. Using scan tool, set engine speed to 1400 RPM. If engine speed is 1300-1500 RPM, return engine to normal idle speed. Idle Air Control (IAC) motor is okay. Test is complete. If engine speed is not 1300-1500 RPM, go to next step.
2. Using scan tool, return engine to normal idle speed. Inspect engine for any vacuum leaks. If vacuum leaks are present, repair vacuum leaks as necessary. Perform TEST VER-2A. If vacuum leaks are not present, go to next step.
3. Disconnect IAC motor connector. Inspect IAC motor connector for damaged or pushed out terminals. If connector is okay, replace IAC motor. Perform TEST VER-2A. If connector is not okay, repair connector as necessary. Perform TEST VER-2A.

TEST NTC-10A - CHECKING PARK/NEUTRAL POSITION SWITCH

Note. Perform TC-114A, NTC-1A or NTC-9A before proceeding.

Note. FJ22 body is equipped with a transmission range sensor.

1. Using scan tool, read park/neutral switch input state. Observe scan tool display while moving gear selector in and out of Park and Reverse. If scan tool displayed P/N and D/R, go to next step. If scan tool did not display P/N and D/R, go to step 4).
2. Condition to set trouble code is not present at this time. PARK/NEUTRAL SWITCH FAILURE DTC sets if Powertrain Control Module (PCM) detects an incorrect Park/Neutral state for a given mode of vehicle operation. Possible causes are: faulty wiring harness connections, park/neutral switch failure, mechanical transmission failure or PCM failure. Go to next step.
3. Inspect all related wiring and connectors and repair as necessary. If no problems were found with wiring and connectors, see INACTIVE TROUBLE CODE CONDITION. Test is complete. Perform TEST VER-2A. If related wiring and connectors were repaired, perform TEST VER-2A. Test is complete.
4. Turn ignition off. Put gear selector in Park. If vehicle is equipped with a 4-speed automatic transmission, go to step 7). If vehicle is not equipped with a 4-speed automatic transmission, go to next step.
5. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, connect ohmmeter lead to Park/Neutral switch sense circuit at PCM connector terminal No. 76. See PCM CONNECTOR WIRE IDENTIFICATION table. While observing resistance reading, move gear selector in and out of Park and Reverse. If resistance switched from less than 5 ohms to more than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance did not switch from less than 5 ohms to more than 5 ohms, go to next step.
6. If resistance stayed less than 5 ohms all the time, repair short to ground on Park/Neutral switch sense circuit. Perform TEST VER-2A. If resistance did not stay less than 5 ohms all the time, go to next step.
7. Disconnect park/neutral switch connector. Using an ohmmeter, check resistance of park/neutral switch sense circuit between 3-pin park/neutral switch connector and PCM connector terminal No. 76. See PCM CONNECTOR WIRE IDENTIFICATION table for wire color identification on PCM connector and 3-pin park/neutral switch connector. If resistance is less than 5 ohms, replace park/neutral switch. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open park/neutral switch sense circuit. Perform TEST VER-2A.
8. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, connect ohmmeter lead to Park/Neutral switch sense circuit at PCM connector terminal No. 76. See PCM CONNECTOR WIRE IDENTIFICATION table. While observing resistance reading, move gear selector in and out of Park and Reverse. If resistance switched from less than 5 ohms to more than 5 ohms, replace PCM. Perform TEST VER-2A. If resistance did not switch from less than 5 ohms to more than 5 ohms, go to next step.
9. If resistance stayed less than 5 ohms all the time, repair short to ground on Park/Neutral switch sense circuit. Perform TEST VER-2A. If resistance did not stay less than 5 ohms all the time, go to next step.
10. Disconnect Transmission Range Sensor (TRS) connector. Using an ohmmeter, check resistance of park/neutral switch sense circuit between 10-pin TRS connector and PCM connector terminal No. 76. See PCM CONNECTOR WIRE IDENTIFICATION table for wire color identification on PCM connector and 10-pin TRS connector. If resistance is less than 5 ohms, replace TRS. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open park/neutral switch sense circuit. Perform TEST VER-2A.

PCM CONNECTOR WIRE IDENTIFICATION

TEST NTC-11A - CHECKING PCM POWER & GROUNDS

Note. Perform NTC-1A or NTC-10A before proceeding.

1. Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. Using an ohmmeter, check resistance of PCM ground circuits. See PCM CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or less for any ground circuit, go to next step. If resistance is more than 5 ohms, repair ground circuit for high resistance. Perform TEST VER-2A.
2. Using a voltmeter, check voltage of PCM fused B+ circuit. If voltage is 10 volts or more, go to next step. If voltage is less than 10 volts, repair open fused B+ circuit. Perform TEST VER-2A.
3. Turn ignition on. Using a voltmeter, check voltage of PCM fused ignition switch output circuit. If voltage is 10 volts or more, go to next step. If voltage is less than 10 volts, repair open fused ignition switch output circuit. Perform TEST VER-2A.
4. Turn ignition off. Reconnect PCM connectors. PCM power and ground circuits are okay. Test is complete.

PCM CONNECTOR WIRE IDENTIFICATION

TEST NTC-12A - CHECKING EVAPORATIVE EMISSIONS SYSTEMS

Note. Perform NTC-1A or NTC-11A before proceeding.

1. Start engine. Allow engine to reach normal operating temperature of 180°F (82°C). Inspect vacuum line from throttle body to EVAP solenoid. Check for vacuum leaks or restrictions. If vacuum line is okay, go to next step. If vacuum line is not okay, repair vacuum line as necessary. Perform TEST VER-2A.
2. Start engine. Allow engine to reach normal operating temperature of 180°F (82°C). Turn engine off. Disconnect vacuum line at EVAP solenoid that goes to EVAP canister. Start engine. There should not be airflow through EVAP solenoid for 1-2 minutes after starting engine. If EVAP solenoid does not allow vacuum to pass within one minute, go to next step. If EVAP solenoid is allowing vacuum to pass within one minute, replace EVAP solenoid. Perform TEST VER-2A.
3. After 90 seconds, EVAP solenoid should allow vacuum to cycle through intermittently at a steady rate. If EVAP solenoid is allowing vacuum to cycle through intermittently at a steady rate, go to next step. If EVAP solenoid is not allowing vacuum to cycle through intermittently at a steady rate, replace EVAP solenoid. Perform TEST VER-2A. CAUTION: DO NOT use more than 5 psi (.35 kg/cm 2 ) when performing the following steps.
4. Turn ignition off. Attempt to blow air through the vacuum line that goes to EVAP canister. If EVAP canister and vacuum line allow air to pass, purge solenoid and hoses are okay. Test is complete. If EVAP canister and vacuum line do not allow air to pass, go to next step.
5. Disconnect vacuum line at EVAP canister side that goes to EVAP solenoid. Attempt to blow air through vacuum line that goes to canister. If vacuum line allows air to pass, replace EVAP canister. Perform TEST VER-2A. If vacuum line does not allow air to pass, repair or replace vacuum line. Perform TEST VER-2A.

TEST NTC-13A - CHECKING EGR SYSTEM

Note. Perform TEST NTC-1A or NTC-12A before proceeding.

1. Disconnect vacuum supply hose at EGR solenoid. The EGR solenoid is located on top of EGR backpressure transducer.
2. Install vacuum gauge on disconnected vacuum supply hose. Start engine. If vacuum is more than 10 in. Hg at idle, go to step 4). If vacuum is 10 in. Hg or less at idle, go to next step.
3. Disconnect EGR solenoid vacuum supply hose at intake manifold. Install a vacuum gauge onto intake manifold nipple. Note vacuum reading with engine idling. If vacuum is more than 10 in. Hg at idle, repair restriction or leak in vacuum supply hose to EGR solenoid. Perform TEST VER-2A. If vacuum is 10 in. Hg or less at idle, repair plugged vacuum port on intake manifold. Perform TEST VER-2A.
4. Disconnect vacuum gauge. Reconnect vacuum supply hose at EGR solenoid. Disconnect EGR valve hose from top of EGR valve. Connect a vacuum gauge to disconnected hose. While observing vacuum gauge, unplug EGR solenoid electrical connector. Raise engine speed slightly above idle and observe vacuum reading. If vacuum reading is more than 3 in. Hg, go to next step. If vacuum reading is 3 in. Hg or less, replace EGR valve assembly. Perform TEST VER-2A.
5. Turn ignition off. Disconnect exhaust backpressure hose from bottom of EGR backpressure transducer. Adjust shop air supply to 20 psi (1.4 kg/cm 2 ). Using shop air supply adjusted to 20 psi (1.4 kg/cm 2 ), connect shop air to nipple on base of backpressure transducer. Backpressure transducer has EGR solenoid mounted on top of it. While opening and closing throttle, listen for a tone change. If tone changes, replace EGR valve assembly. Perform TEST VER-2A. If tone does not change, go to next step.
6. Remove vacuum gauge. Cap open nipple at EGR backpressure transducer. Connect a hand vacuum pump to EGR valve nipple located on base EGR valve. Start engine. Apply vacuum to EGR valve. Listen for an engine speed change. If engine speed stayed the same, replace EGR valve assembly. Perform TEST VER-2A. If engine speed did not stay the same, go to next step.
7. Turn ignition off. Apply 10 in. Hg of vacuum to nipple on base of EGR valve and hold for 30 seconds. If vacuum held for 30 seconds, EGR system is functioning normal. Test is complete. If vacuum did not hold for 30 seconds, replace EGR valve assembly. Perform TEST VER-2A.

TEST NTC-14A - CHECKING ENGINE VACUUM

Note. Perform TEST NTC-1A or NTC-13A before proceeding.

1. Connect vacuum gauge to a manifold engine vacuum source. Start engine and allow to idle. Note engine vacuum reading. Turn engine off.
2. Engine vacuum should be steady and 13-22 in. Hg depending on the altitude. If engine vacuum is not within specification, perform NTC-18A. If engine vacuum is within specification, engine vacuum is normal. Test is complete.

TEST NTC-15A - CHECKING INTAKE AIR TEMPERATURE SENSOR

Note. Perform TEST TC-118A, NTC-1A or NTC-14A before proceeding. When performing this test, DO NOT allow more than 5 minutes between measuring temperature of intake air temperature sensor with scan tool and measuring the air temperature on inside of intake manifold with temperature probe.

1. Turn ignition on with engine off. Using scan tool, read and record Intake Air Temperature (IAT) sensor reading. Turn ignition off. Remove Manifold Absolute Pressure (MAP) sensor. Using a temperature probe, measure air temperature inside MAP sensor opening in intake manifold.
2. If IAT sensor reading is within 10°F (-12°C) of air temperature probe reading, reconnect MAP sensor. IAT sensor is functioning properly. Test is complete. If IAT sensor reading is not within 10°F (-12°C) of air temperature probe reading, replace IAT sensor. Perform TEST VER-2A.

TEST NTC-17A - CHECKING MINIMUM IDLE AIRFLOW

Note. Perform TEST NTC-1A or NTC-16A before proceeding.

1. Turn ignition off. Disconnect PCV valve hose from PCV valve. Plug PCV valve hose. Disconnect 3/16" idle purge hose from throttle body. Using a small piece of hose, install Orifice (6457) (orifice size is .125") to throttle body.
2. Start engine. Allow engine to reach normal operating temperature. Using scan tool, actuate minimum airflow. If throttle body minimum airflow idle RPM is not 500-1000 RPM, go to next step. If throttle body minimum airflow idle RPM is 500-1000 RPM. Using scan tool, stop minimum airflow actuation. Minimum airflow is normal. Test is complete.
3. Using scan tool, stop minimum airflow actuation. Turn engine off. Remove throttle body. With throttle fully open on throttle body, clean throttle body with parts cleaner. Using soft brush or pad, ensure throttle body bore and throttle plate are clean. Dry throttle body with compressed air.
4. Reinstall throttle body. Recheck throttle body minimum airflow. If throttle body minimum airflow idle RPM is 500-1000 RPM, throttle body is okay. Test is complete. Perform TEST VER-2A. If throttle body minimum airflow idle RPM is not 500-1000 RPM, replace throttle body. Perform TEST VER-2A.

TEST NTC-18A - CHECKING ENGINE MECHANICAL SYSTEMS

Note. Perform TEST TC-118A, TC-119A or NTC-7A before proceeding.

Note. If coming to this test from an oxygen sensor test, and rich or lean condition is not corrected after checking items listed below, replace Powertrain Control Module (PCM). Perform TEST VER-2A.

At this point in diagnostic test procedure, all engine control systems have been determined to be operating as designed and not causing a driveability problem. Following additional items should be checked as possible causes

1. Check for Technical Service Bulletins (TSBs) relating to driveability problem.
2. Check engine vacuum. Engine vacuum must be at least 13 in. Hg in with transmission in Neutral.
3. Check engine valve timing.
4. Check engine compression.
5. Check camshaft lobes for abnormal wear.
6. Check crankshaft sensor pick-up. Check crankshaft slots for debris or deterioration.
7. Check exhaust system for restrictions.
8. Ensure PCV system is functioning properly.
9. Check camshaft and crankshaft sprockets for proper position.
10. Check torque converter stall speed.
11. Check power brake booster for internal vacuum leak.
12. Check fuel for contamination.
13. Ensure proper injector driver wiring is installed on correct injector. Ensure injector is not plugged or restricted.

TEST NS-SEL - NO START SELECTION MENU

Battery must be fully charged before performing any tests. If battery is low, charge battery and then attempt to start vehicle. If vehicle will not start, crank engine for 15 seconds, 3 consecutive times. Cranking engine will allow any trouble codes to set which may have been erased from a dead battery. Using scan tool, read trouble codes. Repair any set trouble codes before continuing with no start diagnosis.

To correct a no start problem, begin with TEST NS-1A. TEST NS-1A will lead through testing as required to fix vehicle. If a particular symptom is present and only that symptom is being diagnosed, see NO START SELECTION MENU table. Check Technical Service Bulletins (TSBs) for any pertinent information. If a TSB exists, perform corrective procedure as instructed.

NO START SELECTION MENU

TEST NS-1A - QUALIFYING A NO START CONDITION

Note. Perform TEST NS-SEL before proceeding. Perform all trouble code testing that affects vehicles ability to start before proceeding.

1. Attempt to crank engine. If engine was able to crank, go to next step. If engine was not able to crank, go to TEST NS-9A.
2. Using scan tool, read current Camshaft Position (CMP) state and Crankshaft Position (CKP) state. Crank engine for a least 15 seconds. If scan tool displays CURRENT CKP STATE PRESENT while cranking, go to next step. If scan tool does not display CURRENT CKP STATE PRESENT while cranking, go to TEST TC-40A.
3. If scan tool displays CURRENT CMP STATE PRESENT while cranking, go to TEST NS-1B. If scan tool does not display CURRENT CMP STATE PRESENT while cranking, go to TEST TC-1A.

TEST NS-1B - QUALIFYING A NO START CONDITION

Note. Perform TEST NS-1A before proceeding.

1. Disconnect cylinder No. 2 spark plug wire. Insert an insulated screwdriver in plug wire end. Hold screwdriver within 1/4" of ground. While observing for spark, crank engine for 10 seconds. Consider one or 2 sparks as a no spark condition. If good spark is present, go to TEST NS-2A. If good spark is not present, go to next step.
2. Reconnect spark plug wire. Remove distributor cap. Put one end of a spark plug wire into high tension tower of distributor. Insert an insulated screwdriver into other end of spark plug wire. Hold screwdriver within1/4" of ground. Go to next step.
3. While observing for spark, crank engine for 10 seconds. Consider one or 2 sparks as a no spark condition. If good spark is present, replace distributor cap and rotor. Perform TEST VER-1A. If good spark is not present, go to next step.
4. Disconnect distributor 2-pin connector. Turn ignition on. Using scan tool, actuate ignition coil. Using a voltmeter, check voltage of ASD relay output circuit Black/Red wire at distributor 2-pin connector. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ASD relay output circuit. Perform TEST VER-1A.
5. Turn ignition off. Disconnect distributor 6-pin connector. Using an ohmmeter, check resistance of ground circuit Black wire (not sensor ground circuit) at distributor 6-pin connector. (Scheme 110) If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open ground circuit. Perform TEST VER-1A. NOTE: Next step checks PCMs ability to drive ignition coil driver circuit. An analog voltmeter capable of detecting 0.1 volt is necessary to perform test step.
6. Turn ignition on. Connect an analog voltmeter between ignition coil driver circuit and ground circuit at distributor 6-pin connector. (Scheme 110) Using scan tool, actuate ignition coil. If voltmeter shows a pulsating deflection, go to next step. If voltmeter does not show a pulsating deflection, go to step 8).
7. Check engine valve timing. If engine valve timing is within specification, replace ignition coil. Perform TEST VER-1A. If engine valve timing is not within specification, repair engine valve timing as necessary. Perform TEST VER-1A.
8. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of ignition coil driver circuit Red/Dark Green wire distributor 6-pin connector. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on ignition coil driver circuit. Perform TEST VER-2A.
9. Using an ohmmeter, check resistance of ignition coil driver circuit Red/Dark Green wire between distributor 6-pin connector and PCM connector terminal No. 11. If resistance is more than 5 ohms, repair open ignition coil driver circuit. Perform TEST VER-1A. If resistance is 5 ohms or less, replace PCM. Perform TEST VER-2A.

Identifying Distributor 6-Pin Connector. Scheme 110

TEST NS-2A - CHECKING FUEL SYSTEM

Note. Perform TEST DTC before proceeding.

1. Ensure throttle cables are not holding throttle open. If throttle is being held open, repair as necessary. Perform TEST VER-1A. If throttle is not being held open, go to next step.
2. Using scan tool, read Throttle Position (TP) sensor voltage. If voltage is more than 1.5 volts, go to next step. If voltage is 1.5 volts or less, go to step 4).
3. Disconnect TP sensor connector. Inspect TP sensor connector for pushed out terminals or damage. If TP sensor connector is okay, replace TP sensor. Perform TEST VER-1A. If TP sensor connector is damaged, repair as necessary. Perform TEST VER-1A.
4. If vehicle is equipped with a factory theft security system, go to next step. If vehicle is not equipped with a factory theft security system, go to step 6).
5. Using scan tool, read theft security system status. If scan tool shows fuel is on, go to next step. If scan tool does not show fuel is on, perform theft security system status. See appropriate ANTI-THEFT SYSTEM article in ACCESSORIES & EQUIPMENT.
6. Using scan tool, actuate ASD fuel system. Check for fuel pump operation at fuel tank. If fuel pump operates, go to next step. If fuel pump does not operate, go to TEST NS-5A.
7. Using scan tool, stop ASD fuel system actuation. Turn ignition off. Ensure fuel tank is at least 1/4 full before performing this test. Release fuel pressure. Install fuel pressure gauge to fuel rail. Go to next step.
8. Turn ignition on. Using scan tool, actuate ASD fuel system. Read fuel pressure gauge. See FUEL PRESSURE SPECIFICATION table. If fuel pressure is within specification, go to next step. If fuel pressure is more than specification, perform TEST NS-4B. If fuel pressure is less than specification, perform TEST NS-4A. FUEL PRESSURE SPECIFICATION Application psi (kg/cm 2 ) FJ22 Body 47-50 (3.3-3.5)
9. Using scan tool, stop ASD fuel system actuation. Attempt to start vehicle. If vehicle started and stalled repeatedly, go to TEST NS-7A. If vehicle did not start and stall repeatedly, fuel pressure is okay. Go to TEST NS-3A.

TEST NS-3A - CHECKING ENGINE MECHANICAL SYSTEMS

Note. Perform TEST NS-2A before proceeding.

1. Check for proper spark plug wire routing and firing order. On 2.5L engine, firing order is 1-2-3-4-5-6 with cylinder No. 1 located on passenger side of engine compartment (rear cylinder head). If spark plug wire routing is incorrect, repair as necessary. Perform TEST VER-1A. If spark plug wire routing is correct, go to next step.
2. Turn ignition off. Check engine valve timing. If engine valve timing is okay, go to next step. If engine valve timing is not okay, repair engine valve timing as necessary. Perform TEST VER-1A.
3. Remove all spark plugs. Inspect sparks plugs for wetness caused by fuel. If spark plugs are not wet, go to next step. If spark plugs are wet, clean spark plugs and go to next step.
4. Check compression on all cylinders. See «SPECIFICATIONS - 2.5L»(ref-24732) article for compression specifications. If compression is within specification, reinstall all disconnected components. Attempt to start engine. If engine starts and stays running, test is complete. Perform TEST VER-1A. If engine will not start or stay running, go to TEST NS-8A.

TEST NS-4B - REPAIRING HIGH FUEL PRESSURE

Turn ignition off. Ensure fuel tank is at least 1/4 full before performing this test. Release fuel pressure. Remove fuel pressure regulator. Inspect fuel return line for restriction between fuel filter and fuel pump module. If a restriction is present, repair fuel return line from fuel pressure regulator to fuel tank. Perform TEST VER-1A. If a restriction is not present, replace fuel pressure regulator and fuel filter. Perform TEST VER-1A.

TEST NS-4C - REPAIRING LOW FUEL PRESSURE

1. With scan tool still actuating ASD fuel system, gently squeeze fuel return hose. Observe fuel pressure gauge. If fuel pressure is more than 46 psi (3.2 kg/cm 2 ), stop ASD fuel system actuation. Replace fuel pressure regulator. Perform TEST VER-1A. If fuel pressure is 45 psi (3.1 kg/cm 2 ) or less, go to next step.
2. Using scan tool, stop ASD fuel system actuation. Inspect fuel lines between fuel rail and fuel pump for a kink or restriction. If a kink or restriction is present, repair as necessary. Perform TEST VER-1A. If a kink or restriction is not present, go to next step.
3. Release fuel pressure. Remove fuel filter. Inspect fuel filter for a restriction. If fuel filter is restricted, ensure fuel tank is not contaminated and replace fuel filter. Perform TEST VER-1A. If fuel filter is not restricted, reinstall fuel filter. Ensure fuel tank is not contaminated and replace fuel pump and inlet strainer. Perform TEST VER-1A.

TEST NS-5A - CHECKING FUEL PUMP

Note. Perform TEST NS-2A before proceeding.

1. Turn ignition off. Disconnect fuel pump relay. For fuel pump relay location see scheme 72through 212. Using a voltmeter, check voltage on fuel pump relay connector fused B+ circuit. see scheme 72through 212. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused B+ circuit. Perform TEST VER-1A.
2. Install a substitute relay. Attempt to start engine. If engine does not start, go to next step. If engine started, replace fuel pump relay. Perform TEST VER-1A.
3. Reinstall original fuel pump relay. Disconnect fuel pump harness connector. See FUEL PUMP CONNECTOR LOCATION table. Turn ignition on. Using scan tool, actuate ASD fuel system. Using a voltmeter, check voltage of fuel pump relay output circuit at fuel pump connector (harness side). See CONNECTOR IDENTIFICATION. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fuel pump relay output circuit. Perform TEST VER-1A.
4. Turn ignition off. Using an ohmmeter, check resistance of fuel pump ground circuit at fuel pump connector (harness side) Black wire. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open fuel pump ground circuit. Perform TEST VER-1A.
5. Replace fuel pump. Perform TEST VER-1A.
6. Inspect fuel pump jumper harness. If fuel pump jumper harness is okay, replace fuel pump. Perform TEST VER-1A. If fuel pump jumper harness is not okay, repair or replace jumper harness as necessary.

FUEL PUMP CONNECTOR LOCATION

TEST NS-6A - REPAIRING NO RESPONSE CONDITION

Note. Perform TEST DTC before proceeding.

1. If vehicle starts, go to TEST NS-6B. If vehicle does not start, disconnect Throttle Position (TP) sensor connector. Turn ignition on. Using a voltmeter, check voltage on TP sensor 5-volt supply circuit. See TP SENSOR WIRE IDENTIFICATION table. If voltage is 6 volts or less, go to next step. If voltage is more than 6 volts, repair open grounds at Powertrain Control Module (PCM) connector terminals No. 10, 47 or 50. Perform TEST VER-1A. TP SENSOR CONNECTOR WIRE IDENTIFICATION Application Wire Color TP Sensor Signal Circuit Brown/Red TP Sensor 5-Volt Supply Circuit Dark Green/Yellow TP Sensor Ground Circuit Black/Dark Green
2. Turn ignition off. Disconnect Powertrain Control Module (PCM) connector. Turn ignition on. Using a voltmeter, check voltage of fused ignition switch output circuit at PCM connector terminal No. 20. See PCM CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open fused ignition switch output circuit between PCM connector and ignition switch (also check fuse). Perform TEST VER-1A. PCM CONNECTOR WIRE IDENTIFICATION Application Wire Color PCM Ground Circuit PCM Terminal No. 10 Black PCM Terminal No. 50 Black PCM Fused B+ Circuit: PCM Terminal No. 46 Red/Black PCM Fused Ignition Switch Output Circuit: PCM Terminal No. 20 Black/White
3. Using a voltmeter, check voltage of fused B+ circuit at PCM connector terminal No. 46. See PCM CONNECTOR WIRE IDENTIFICATION table. If voltage is more than 10 volts, go to TEST NS-6B. If voltage is 10 volts or less, go to next step.
4. Remove PCM B+ fuse from Power Distribution Center (PDC) in engine compartment. Inspect fuse. If fuse is okay, go to next step. If fuse is not okay, go to step 6).
5. Using a voltmeter, check voltage on battery voltage side of fuse socket. If voltage is more than 10 volts, repair open between fuse and PCM connector terminal No. 46. Perform TEST VER-1A. If voltage is 10 volts or less, repair open between battery voltage side of fuse socket and battery. Perform TEST VER-1A.
6. Turn ignition off. Disconnect Auto Shutdown (ASD) relay. ASD relay is located in left rear corner of engine compartment.
7. Disconnect fuel pump relay. For fuel pump relay location see scheme 75 Go to next step. see scheme 75: Locating Fuel Pump Relay see scheme 76: Identifying Fuel Pump Relay Connector Terminals
8. Using an ohmmeter, check resistance of fused B+ circuit at PCM connector terminal No. 46. See PCM CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on fused B+ circuit. Replace PCM B+ fuse. Perform TEST VER-1A.
9. Disconnect all O2S connectors. See O2 SENSOR IDENTIFICATION table. Using an ohmmeter, measure resistance between ASD relay output circuit (White wire) and ground. See O2S CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE) table. If resistance is less than 5 ohms for any O2 sensor, replace O2 sensor that had low resistance. Perform TEST VER-1A. If resistance is 5 ohms or more, go to next step. O2 SENSOR IDENTIFICATION Application Location O2S 1/1 Rear Bank Upstream O2S O2S 1/2 Rear Bank Downstream O2S O2S 2/1 Front Bank Upstream O2S O2S 2/2 Front Bank Downstream O2S O2S CONNECTOR WIRE IDENTIFICATION (COMPONENT SIDE) Application Wire Color O2S 1/1 Signal Circuit Black O2S 1/1 ASD Relay Output Circuit White O2S 1/1 Heater Ground Circuit White O2S 1/1 Ground Circuit Gray
10. Remove ASD relay. ASD relay is located in left rear corner of engine compartment.
11. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, go to step 14). see scheme 77: Identifying ASD Relay Connector Terminals & Location
12. Disconnect fuel pump harness connector. See FUEL PUMP CONNECTOR LOCATION table. Remove fuel pump relay. For fuel pump relay location see scheme 75 Using an ohmmeter, check resistance of fuel pump relay output circuit at fuel pump relay connector (harness side). See FUEL PUMP CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on fuel pump relay output circuit. Replace fuse. Perform TEST VER-1A. FUEL PUMP CONNECTOR LOCATION Application Location FJ22 Body Under Right Side Of Rear Seat FUEL PUMP CONNECTOR WIRE IDENTIFICATION Application Wire Color Fuel Pump Relay Output Circuit Black/Dark Blue
13. Inspect fuel pump relay output circuit for a possible intermittent short to ground. If an intermittent short to ground is present, repair as necessary. Replace fuse. Perform TEST VER-1A. If an intermittent short to ground is not present, replace fuel pump. Replace fuse. Perform TEST VER-1A. NOTE: Ensure all O2 sensor connectors remain disconnected for remainder of test procedure.
14. Disconnect ignition coil connector. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, replace ignition coil. Replace fuse. Perform TEST VER-1A.
15. Disconnect generator field connector. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair generator for a short to ground. Replace fuse. Perform TEST VER-1A.
16. Disconnect injector No. 1 electrical connector. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, replace injector No. 1. Replace fuse. Perform TEST VER-1A.
17. Disconnect injector No. 2 electrical connector. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, replace injector No. 1. Replace fuse. Perform TEST VER-1A.
18. Disconnect injector No. 3 electrical connector. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, replace injector No. 1. Replace fuse. Perform TEST VER-1A.
19. Disconnect injector No. 4 electrical connector. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, replace injector No. 1. Replace fuse. Perform TEST VER-1A.
20. If vehicle is equipped with a V6 engine, go to next step. If vehicle is not equipped with a V6 engine, repair short to ground on ASD relay output circuit. Replace fuse. Perform TEST VER-1A.
21. Disconnect injector No. 5 electrical connector. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, replace injector No. 1. Replace fuse. Perform TEST VER-1A.
22. Disconnect injector No. 6 electrical connector. Using an ohmmeter, check resistance of ASD relay output circuit at ASD relay connector. see scheme 77for wire identification. If resistance is 5 ohms or less, repair short to ground on ASD relay output circuit. Replace fuse. Perform TEST VER-1A. If resistance is more than 5 ohms, replace injector No. 1. Replace fuse. Perform TEST VER-1A.

TEST NS-6B - REPAIRING NO RESPONSE CONDITION

Note. Perform TEST NS-6A before proceeding.

TEST NS-6B does not apply to this vehicle. Go to TEST NS-6C.

TEST NS-6C - REPAIRING NO RESPONSE CONDITION

Note. Perform TEST NS-6B before proceeding.

1. If ignition was on when NO RESPONSE message was displayed, go to next step. If ignition was off when NO RESPONSE message was displayed, turn ignition on to get a response. Test is complete.
2. Turn ignition off. Disconnect scan tool from data link connectors. Disconnect Powertrain Control Module (PCM) connector. Using an ohmmeter, check resistance of Serial Communications Interface (SCI) transmit wire at 16-pin data link connector. See DATA LINK CONNECTOR WIRE IDENTIFICATION table. Go to next step. DATA LINK CONNECTOR WIRE IDENTIFICATION Application Wire Color 12-Pin Data Link Connector: SCI Engine Receive Circuit Dark Blue/Pink 16-Pin Data Link Connector: SCI Transmit Circuit Pink
3. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on SCI transmit circuit. Perform TEST VER-1A.
4. Using an ohmmeter, check resistance of Serial Communications Interface (SCI) engine receive wire at 12-pin data link connector. See DATA LINK CONNECTOR WIRE IDENTIFICATION table. If resistance is 5 ohms or more, go to next step. If resistance is less than 5 ohms, repair short to ground on SCI engine receive circuit. Perform TEST VER-1A.
5. Using an ohmmeter, check resistance of SCI transmit wire between 16-pin data link connector and Powertrain Control Module (PCM) connector terminal No. 65. See DATA LINK CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open SCI transmit circuit. Perform TEST VER-1A.
6. Using an ohmmeter, check resistance of SCI engine receive wire between 12-pin data link connector and PCM connector terminal No. 75. See DATA LINK CONNECTOR WIRE IDENTIFICATION table. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open SCI engine receive circuit. Perform TEST VER-1A.
7. Connect scan tool to a functional data link connector on another vehicle. Turn ignition on. Using scan tool, attempt to read trouble codes. If scan tool displays NO RESPONSE, go to next step. If scan tool does not display NO RESPONSE, replace initial vehicles Powertrain Control Module (PCM). Perform TEST VER-1A.
8. Substitute another scan tool adapter cable. Using scan tool, attempt to read trouble codes. If scan tool displays NO RESPONSE, repair or replace scan tool. If scan tool does not display NO RESPONSE, replace scan tool adapter cable.

TEST NS-8A - REPAIRING A START & STALL CONDITION

Note. Perform TEST NS-7A before proceeding.

At this point in diagnostic test procedure, all engine electrical control systems have been determined to be operating as designed and not causing a start and stall problem. Following additional items should be checked as possible causes

1. Check for Technical Service Bulletins (TSBs) relating to start and stall condition.
2. Check valve timing.
3. Check engine compression.
4. Check exhaust system for restrictions.
5. Ensure PCV system is functioning properly.
6. Check for proper position of engine drive sprockets.
7. Check fuel for contamination.
8. Check secondary ignition system.

TEST NS-9A - REPAIRING A NO CRANK CONDITION

Note. Perform TEST NS-1A before proceeding.

Scheme 111

Scheme 112

1. If vehicle is equipped with a manual transmission, go to TEST NS-9B. If vehicle is equipped with an automatic transmission, go to next step.
2. Ensure transmission is in Park. Using scan tool, read Park/Neutral (PN) switch sense. If PN switch senses park, go to next step. If PN switch does not sense park, replace open PN switch. Perform TEST VER-1A.
3. Disconnect starter relay. Using a voltmeter, check voltage on starter relay connector fused B+ circuit. Starter relay is located behind right side of center console. (Scheme 111) For circuit identification (Scheme 112)through 228. If voltage is more than 11.6 volts, go to next step. If voltage is 11.6 volts or less, repair open fused B+ circuit. Perform TEST VER-1A. (Scheme 111): Locating Starter Relay (Scheme 112): Identifying Starter Relay Connector Terminals
4. Using a voltmeter, check voltage of ignition switch output circuit at starter relay connector. While observing voltmeter, turn ignition switch to START position. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ignition switch output (start) circuit. Perform TEST VER-1A. WARNING: Engine may crank in following step, keep away from moving engine parts.
5. Ensure transmission is in Park and parking brake is set. Using a jumper wire, briefly connect starter relay output circuit to fused B+ circuit at starter relay connector. For circuit identification (Scheme 112)through 228. If starter cranks engine, go to step 9). If starter did not crank engine, go to next step.
6. If starter solenoid clicked when jumper wire was connected, go to next step. If starter solenoid did not click when jumper wire was connected, disconnect jumper wire. Disconnect starter solenoid 1-pin connector. See STARTER SOLENOID CONNECTOR WIRE IDENTIFICATION table. Using an ohmmeter, check resistance of starter relay output circuit at 1-pin connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open starter relay output circuit. Perform TEST VER-1A. STARTER SOLENOID CONNECTOR WIRE IDENTIFICATION Application Wire Color Starter Relay Output Circuit Black/Yellow
7. Reinstall starter relay. Check battery cables for high resistance. If either battery cable had a voltage drop of more than.2 volt, repair or replace battery cable for high resistance. Perform TEST VER-1A. If either battery cable did not have a voltage drop of more than.2 volt, go to next step.
8. Attempt to manually rotate crankshaft 360 degrees. If crankshaft was able to rotate 360 degrees, replace starter motor. Perform TEST VER-1A. If crankshaft was not able to rotate 360 degrees, repair engine mechanical failure as necessary. Perform TEST VER-1A.
9. Using an ohmmeter, check resistance of Park/Neutral (PN) switch sense circuit at starter relay connector. For circuit identification (Scheme 112)through 228. If resistance is less than 5 ohms, replace starter relay. Perform TEST VER-1A. If resistance is 5 ohms or more, repair open PNP switch sense circuit between starter relay connector and splice. Perform TEST VER-1A.

TEST NS-9B - REPAIRING A NO CRANK CONDITION

Note. Perform TEST NS-9A before proceeding.

1. Disconnect starter relay. Using an ohmmeter, check resistance of starter relay ground circuit at starter relay connector. Starter relay is located behind right side of center console. see scheme 80 For circuit identification see scheme 81through 232. If resistance is more than 5 ohms, repair open starter relay ground circuit. Perform TEST VER-1A. If resistance is 5 ohms or less, go to next step. see scheme 80: Locating Starter Relay see scheme 81: Identifying Starter Relay Connector Terminals
2. Using a voltmeter, check voltage on starter relay connector fused B+ circuit. For circuit identification see scheme 81through 232. If voltage is more than 11.6 volts, go to next step. If voltage is 11.6 volts or less, repair open fused B+ circuit. Perform TEST VER-1A.
3. Using a voltmeter, check voltage of ignition switch output circuit at starter relay connector. While observing voltmeter, turn ignition switch to START position and depress clutch. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open ignition switch output (start) circuit or open clutch switch. Perform TEST VER-1A. WARNING: Engine may crank in following step, keep away from moving engine parts.
4. Ensure transmission is in Neutral and parking brake is set. Using a jumper wire, briefly connect starter relay output circuit to fused B+ circuit at starter relay connector. For circuit identification see scheme 81through 232. If starter cranks engine, replace starter relay. Perform TEST VER-1A. If starter did not crank engine, go to next step.
5. If starter solenoid clicked when jumper wire was connected, go to next step. If starter solenoid did not click when jumper wire was connected, disconnect jumper wire. Disconnect starter solenoid 1-pin connector. See STARTER SOLENOID CONNECTOR WIRE IDENTIFICATION table. Using an ohmmeter, check resistance of starter relay output circuit at 1-pin connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open starter relay output circuit. Perform TEST VER-1A. STARTER SOLENOID CONNECTOR WIRE IDENTIFICATION Application Wire Color Starter Relay Output Circuit Black/Yellow
6. Reinstall starter relay. Check battery cables for high resistance. If either battery cable had a voltage drop of more than.2 volt, repair or replace battery cable for high resistance. Perform TEST VER-1A. If either battery cable did not have a voltage drop of more than.2 volt, go to next step.
7. Attempt to manually rotate crankshaft 360 degrees. If crankshaft was able to rotate 360 degrees, replace starter motor. Perform TEST VER-1A. If crankshaft was not able to rotate 360 degrees, repair engine mechanical failure as necessary. Perform TEST VER-1A.

TEST VER-1A - NO START VERIFICATION

1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. Inspect engine oil for fuel contamination. Change oil and filter as necessary. Attempt to start engine.
2. If engine does not start, check for Technical Service Bulletins (TSBs) that apply to vehicle and return to DTC TEST, if necessary. Repair is complete.

TEST VER-2A ROAD TEST VERIFICATION

1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. If test is being performed after performing a NO TROUBLE CODE (NTC) test, go to next step. If test is being performed after performing a OBD-II TROUBLE CODE test, perform TEST VER-5. If test is being performed after any other TROUBLE CODE test, go to step 3).
2. Check if initial symptom still exists. If initial or another symptom exists, repair is not complete. Check for Technical Service Bulletins (TSBs) that apply to the symptom and return to TEST NTC-1A, if necessary.
3. If any DTCs have not been diagnosed, go to DTC TEST and finish diagnosing remaining DTCs as necessary. If all DTCs have been diagnosed, go to next step.
4. If Powertrain Control Module (PCM) has not been changed, using scan tool, erase DTCs from PCM. Using scan tool, reset all values in adaptive memory. Disconnect scan tool. To ensure no other DTCs remain, go to next step.
5. If this test is for an A/C relay control circuit DTC, ensure vehicle is road tested for at least 5 minutes with A/C on. For all DTCs, road test vehicle at a speed of at least 40 MPH. During road test, stop vehicle and turn engine off for at least 10 seconds or more. Restart engine and continue road test. Ensure transaxle shifts through all gears. After road test, turn engine off. Go to next step.
6. Using scan tool, check for stored DTCs. If repaired DTC has reset, repair is not complete. Check for related Technical Service Bulletins (TSBs) and return to DTC TEST, if necessary. If another DTC exists, return to DTC TEST and follow path specified by other DTC. If no other DTCs exist, repair is now complete.

TEST VER-3A - CHARGING VERIFICATION

1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. If Powertrain Control Module (PCM) has been changed, go to next step. If PCM has not been changed, go to step 3).
2. If vehicle is equipped with factory vehicle theft security system, start vehicle at least 20 times so vehicle theft security system can be activated when desired. Using scan tool, erase DTCs from PCM.
3. To ensure no charging system problem exists, start engine. Increase engine speed to 2000 RPM for at least 30 seconds. Allow engine to idle. Turn engine off.
4. Turn ignition on. Using scan tool, check for stored DTCs. If repaired DTC has reset, repair is not complete. Check for related Technical Service Bulletins (TSBs) and return to DTC TEST, if necessary. If another DTC exists, return to DTC TEST test and follow specified procedure specified by other DTC. If no other DTCs exist, repair is now complete.

TEST VER-4A - SPEED CONTROL VERIFICATION

1. Inspect vehicle to ensure all engine and speed control system components are connected. Reassemble and reconnect components as necessary. If Powertrain Control Module (PCM) has been changed, go to next step. If PCM has not been changed, go to step 3).
2. If vehicle is equipped with factory vehicle theft security system, start vehicle at least 20 times so vehicle theft security system can be activated when desired. Using scan tool, erase DTCs from PCM.
3. To ensure no speed control system problem exists, road test vehicle at a speed greater than 35 MPH. Depress steering wheel speed control ON/OFF switch to ON position. Depress and release steering wheel speed control SET switch.
4. If speed control engages, go to next step. If speed control does not engage, repair is not complete. Check for related Technical Service Bulletins (TSBs) and return to DTC TEST, if necessary.
5. On stalk switch equipped vehicles, quickly depress and release SET switch. On steering wheel switch equipped vehicles, quickly depress and release RESUME/ACCEL switch. On all vehicles, if vehicle speed increases by 2 MPH, go to next step. If vehicle speed does not increase by 2 MPH, repair is not complete. Check for related TSBs and return to DTC TEST, if necessary.
6. Using caution, depress and release brake pedal. If speed control disengages, go to next step. If speed control does not disengage, repair is not complete. Check for related TSBs and return to DTC TEST, if necessary.
7. Increase vehicle speed to 35 MPH. Depress speed control RESUME/ACCEL switch. If vehicle resumes to original speed, go to next step. If vehicle does not resume to original speed, repair is not complete. Check for related TSBs and return to DTC TEST, if necessary.
8. Hold speed control DECEL switch downward. If vehicle speed decreases, go to next step. If vehicle speed does not decrease, repair is not complete. Check for related TSBs and return to DTC TEST, if necessary.
9. Ensure vehicle speed is greater than 35 MPH. Release speed control DECEL switch. If vehicle speed adjusts and sets at a new vehicle speed, go to next step. If vehicle speed does not adjust and set at a new vehicle speed, repair is not complete. Check for related TSBs and return to DTC TEST, if necessary.
10. Turn speed control ON/OFF switch to OFF position. If speed control disengages, system is operating correctly. Repair is complete. If speed control does not disengage, repair is not complete. Check for related TSBs and return to DTC TEST, if necessary.

TEST VER-5A - ROAD TEST FOR OBD-II TROUBLE CODES

1. Inspect vehicle to ensure all engine components are connected. Reassemble and reconnect components as necessary. If DTCs have not been diagnosed, go to DTC TEST and finish diagnosing remaining DTCs as necessary. If all DTCs have been diagnosed, go to next step.
2. Connect scan tool to data link connector. Ensure fuel tank is at least 1/4 full. Ensure A/C is off.
3. Proper way to ensure DTC is properly repaired, is to allow Powertrain Control Module (PCM) to run the monitor. Monitor operation may be observed on the scan tool. All specified enabling conditions for specified DTC must be met before PCM will operate the monitor.
4. Using scan tool, monitor the pretest enabling conditions until all conditions have been met. Once all enabling conditions are met, observe appropriate monitor for DTC on the scan tool.
5. If repaired DTC has reset or was seen in the monitor while on road test, repair is not complete. Check for related Technical Service Bulletins (TSBs) and return to DTC TEST, if necessary.
6. If another DTC exists, return to DTC TEST and follow path specified by other DTC. If no other DTCs exist, repair is now complete.